water management jaeger group of companies ... · cleartec® biotextil wastewater treatment with...

Cleartec® Biotextil

Wastewater

treatment

with high-

performance

textile fixed

bed


CLEARTECWater Management

Jaeger Group of Companies

Cleartec® Biotextil - Folder

Flexible

High performance

Structured


2

Table of Contents Page

General informationIntroduction 3

Material 4

FunctionalityBiofilm 5

Biological growth 6

IFAS 7

System 8

AdvantagesAdvantages IFAS 10

Specific Advantages Cleartec® Biotextil 11

Fields of applicationMunicipal 12

Industrial 13

Specific applications 14

Profitability and performanceProfitability (Example of use) 15

Performance increase (Example of use) 16

ReferencesDifferent References 18


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We grew up with rubber

Since 1942, when Gummi-Jäger, the pa-rent company of Jäger Umwelt-Technik GmbH & Co.KG, was founded, application-oriented advisory service, material-orien-ted construction and system related deve-lopment are the key for the Jäger Group’s success.

Our competence and efficiency conti-nuously raised according to the customers’ demands.Our success is based on continuous pro-duct innovation, advice independent from the material as well as a friendly, com-petent service and zero-defect philosophy competent service.

The family business in its third generati-on operates worldwide and is a qualified partner in the field of automotive, envi-ronmental and agricultural industry as well as in machine and plant engineering and oil exploration. Over 1.000 employees working in more than 20 sites in Europe, the USA and China aim to ensure that.

Our Philosophy

Thinking across departments and corpo-rate boundaries as well as generating competitive advantages for one’s own company, customers and suppliers: Due to these guiding principles the Jaeger Group of Companies is a professional partner in all branches of machine and plant engi-neering.

Confidence in CooperationSuccessful customer relationships are based on trust. For us, this means reliabili-ty in our promises and actions, fairness in equal partnership and the trustworthiness of the Jäger entrepreneur family.

Liability in partnershipJoint work with the most various suppliers guarantees competitive advantages for our customers.

Understanding in problem solutionBy the combination of the most different materials and the integration of various functions in a system component we gua-rantee our customers a lasting advantage in competition.


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With the product Cleartec® Biotextil the Jaeger Group of Companies expands the portfolio in the filed of aeration solutions. The advantages of the structured surface as well as the flexibility of textiles can be used and combined with the proved bio-film technology from wastewater treat-ment. Using high quality raw materials resulted in the high-performance product Cleartec® Biotextil - made in Germany.

The material

Cleartec® Biotextil is made of the materi-al Polypropylene (PP) and used as textile media for microorganisms in municipal and industrial WWTP as well as for special applications.

The advantages

Due to the high affinity of bacteria for po-lypropylene (PP) it is the optimal basic for our media. Furthermore PP is very re-sistant against mechanical, chemical and biochemical influences and has a high load capacity.The highly structured growth stripes have a high surface roughness and therefore they are ideally for settlement of micro-organisms. Additionally the large specific surface provides more protection for the biofilm.

flexible - high-performance - structured

High fabric density (growth stripes) alter-nates with loose structured zones in the design of textile. These are ideal condi-tions for biomass growth and achieve best flow conditions. A textile consists of 16 growth stripes as standard with double-sided special-knitted synthetic loops and has a width of 0,96 m. A result of the per-manent development and optimization of the product by Cleartec Water Manage-ment GmbH.

Material


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Biofilm

Biofilms are the prototype of life and con-sist of an association of different micro-organisms. Until today this life-form has been assert so that the overwhelming number of microorganisms still exist in natural associations in the form of bio-films.

This feature will be used in the biologi-cal waste water treatment. Biofilms are used suspended, in form of flakes in the activated sludge suspension or sessile at a provided media. Microorganisms use pol-lutants from our waste water as nutrients for energy and cell metabolism and con-tribute to limit eutrophication of waters.

Biofilms are often perceived as thin slimy layer as bacteria produce sticky substan-ces (extracellular polymeric substances) to enable aggregation in biofilms.

This thin slimy layer additionally provi-des protection for microorganisms against chemical and mechanical environmental influences. Therefore biofilms consist of a much higher diversity of organisms as bacteria with longer generation times find an ideal basis for existence.

Biofilms can grow at all surfaces. They are available between gas and liquid phase as well as between liquid and solid pha-se. The solid, on which a biofilm settles down, is called substrate.

Biofilm


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The growth stripes of Cleartec® Biotextil (1) are weaved with loop straps, which ensure an ideal habitat due to the existing high inner surface in the growth stripes.

The oxygen supply of biomass by aerati-on (6) obtains a vertical flow (7) which regulate the thickness of biofilm (2) by removal of old biomass (4) due to the flexibility (3) of the media.

The resulting surface renewal enables creation of new active biomass on the basis of bacterial metabolism processes (5).

Therefore the aeration ensures on the one hand ideal oxygen supply for active bio-mass and regulation of predators resulting of textile flexibility on the other. Mostly the textile media is used in combination with suspended biomass (8).

Biological growth


+ =

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In conventional WWTP’s the sedimenta-tion volume in secondary clarification is the limiting factor for the content of bi-omass in aeration tank. The so-called IFAS process (Integrated Fixed Film Activated Sludge) combined suspended with sessile biomass by installing a synthetic media as growth surface for additional biomass in aeration tank. This combination enables a much higher concentration of biomass and therefore a higher sludge age compa-red to conventional operation.

Due to fixation of the the synthetic media, there is no danger of washing out or es-caping of growth media out of the WWTP.IFAS allows a performance increase of bio-logy up to 100% and more without con-structional measurement for volume en-largement of aeration tank and secondary clarification.+ Performance increase+ Capacity increase+ WITHOUT constructional measurementmakes IFAS unrivaled!

IFAS


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System

Cleartec® Biotextil is used as a system. The textile is fixed into a kind of stainless steel cage, which can be assembled with aerators if required. A complete Cleartec®

Biotextil module consists of:

1. Stainless steel cage

The stainless steel cage is used as holding construction for Cleartec® Biotextil. The textile has two or three loops – depending on the total length. Cleartec® Biotextil can be fixed into the cage by holding tubes with these loops. This cage construction can be hoisted out of tank even during the operation.

2. Cleartec® Biotextil

The textile with its structure provides a high inner surface and ideal conditions for the growth of biofilm. The loops are used for fixing the textile into cage construc-tion. The textile itself can move flexible in flow. This provides a steady abrasion of biomass.

3. Diffuser

Aeration of textiles enables an optimal oxygen supply for biomass. Additionally it provides great flow conditions to keep flexible textile in motion and contributes to abrasion of biomass.


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System

The Cleartec® Biotextil module

With perfectly matching components the modular construction consisting of cage in combination with diffuser and Cleartec® Biotextil guarantees ideal flow conditions at the fixed bed to supply biomass with oxygen, a steady abrasion for surface re-newal and control of higher microorga-nism concentration during operation.

Experiences show that textile media in combination with modular design join the advantages of several biofilm processes. The thickness of biofilm meets an average between thin film and classical biofilm and enables a stable and reliable opera-tion.

Single modules can be hoisted out during operation, e.g. to control the diffusers.

The modular construction provides a fle-xible application, can be customized and ensures low-maintenance operation.

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All advantages at a glance

Advantages IFAS

Performance increase

In comparsion to conventional operation the IFAS system works with suspended and sessil biomass. Beside the increased biomass proportion the sludge age incre-ases at the same time. Therefore more nitrificants settle down, which eliminate nitrogen efficiently. The number of speci-alist also increase due to the high sludge age. This provides removal of persistent substances from industrial waste water. Especially elimination of carbon reaches very high specific degradation rates.

Operation stability in biological process

Advantage of sessile biomass is obvious-ly the high sludge age. Biofilm provides microorganism with high generation time the ideal basis for existence and give them protection due to its structure. The combination of sessile and suspended process increases additionally total bio-mass content. Thereby a year-round nitri-fication performance of up to ≤ 0,1 mg/l can be achieved. This application ensures stable effluent during hydraulic loads as well as during toxic loads and variation in pH. Peaks, such as nitrogen shocks du-ring rainy weather and draining rainwa-ter overflow basin, are removed without “conspicuity in effluent”.

Sludge characteristics

Activated sludge from combined process shows better sedimentation due to shea-ring biomass.With textile fixed bed a lower excess sludge of about 75-110 ml/g is produced whereas the excess sludge during conven-tional process is 140-200 ml/g on average.Due to lower percentage of filamentous bacteria in activated sludge less floating sludge is produced.

Capacity increase

It isn’t necessary to enlarge basin volume for performance increase if the biological stage runs with sessile biomass. IFAS sys-tem creates virtual volume, which can be used for removing pollutants. Depending on design an increase of capacity of more than 100% can be reached without loa-ding the secondary clarification. Additio-nally the sludge characteristics are impro-ved and in comparison to other systems it isn’t necessary to dose chemicals.

Advantages IFAS

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Specific advantages of Cleartec® Biotextil

Textile

Flexibility

Flow of the textile by aeration ensures motion of media during operation. This obtains together with shear forces a bet-ter abrasion of biomass and prevents clogging.

High inner surface

Bacteria can settle down faster due to the structure of growth stripe. Nitrification procides faster at Cleartec® Biotextil in comparison to other fixed bed.The high inner surface and roughness of material determine better grip of biomass at media and result in higher specific de-gradation rates (e.g. very high nitrogen and carbon elimination). Altogether, it contributes a very stable operation of the plant.

Stability/Durability

Cleartec® Biotextil is resistant against che-mical and mechanical influences. This is proved by installation of Cleartec® Bio-textil at reference plants since over 17 ye-ars.

System

Module construction

Construction of module provides an ideal flow of media. Optimal oxygen supply and flexibility of textile lead to a defined bio-film thickness. Combined process achieves a high self-denitrification capacity compa-red to thin film technology. Furthermore the design of module facilitates control of the system concerning predators. The possibility to combine module with aera-tors makes it flexible for all applications and conditions. The textile itself is mainte-nance-free. The system Cleartec® Biotextil is a low-maintenance application. It has only be considered the time for checking and maintaining aggregates.

Specific advantages


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Fields of application

Municipality

IFAS has been especially proved in munici-pal sector. Great nitrification performance and high operation stability, which are reached with IFAS, are important for mu-nicipality.

If legal requirements regarding effluent quality (e.g. nitrogen elimination) are in-creased, the performance of an existing plant can be increased by IFAS without conventional enlargement. That offers a special alternative in case of space for en-largement of the plant does not exist.

Because of low-maintenance or mainte-nance-free operation a further advantage of Cleartec® Biotextil is given for decentral application. Biological process needs no complicated technology and process con-trol and fulfills required cleaning perfor-mance anyway. Thus, it ensures reliability of plant.Moreover, the process offers the possibili-ty to operate with an entirely sessile pro-cess and is ideal for plants, which cannot realize return of sludge.


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Industry

Industry has the choice to treat their was-te water as direct discharger or indirect di-scharger. Companies have to take care of removal of biological and dangerous sub-stances themselves by direct discharge. In connection with this process companies can discharge the cleaned water directly into waters.

Indirect discharger drains waste water in sewers and over a municipal WWTP into waters. However, waste water of indust-ry can contain pollutants, which are not allowed to discharge directly into draina-ge. These incredients have to be removed from waste water. Municipality takes on removal of biological pollutants.

Depending on composition of waste wa-ter, level of taxes for waste water treat-ment und legal requirements it can be useful for both possibilities to run an own WWTP with biological stage.

Cleartec® Biotextil with its hybrid pro-cess of sessile and suspended biomass is suitable for this application. The defined biofilm offers optimal conditions for sett-lement of specialists with high generation times. Thereby a biocenosis, adapted to specific solids, can be developed.

Cleartec® Biotextil can be especially ap-plied for carbon elimination. Therefore Cleartec® Biotextil has already been esta-blished as media in food, textile and phar-maceutical industry. The system is space saving and low-maintenance and for that reason an optimal solution for industrial WWTP’s.



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Special applications

Due to modular usage Cleartec® Biotextil is a flexible product. Thus it is used in mis-cellaneous other fields.The media is available in length from 0,5 up to 4,50 m, variable in width and so ap-plicable for different installations.

Examples:

Pond treatment plants Pond treatment plants are used for was-te water treatment worldwide. Cleartec® Biotextil is optimal to increase treatment efficiency. Due to flexible installation op-tions Cleartec® Biotextil is ideal for appli-cations in a limited space. Beside a pond treatment plant our textile were also ins-talled in a cleaning plant of a water cycle at the zoo in Zurich.

Floating reactorA further project with Cleartec® Biotextil is the floating reactor for improving water quality in flowing and standing urban wa-ters. Thereby the textile is fixed in a type of swimming cage and insert into waters. Application is benefited by high perfor-mance of Cleartec® Biotextil, which allows great performance with simple technolo-gy.



Cleartec® Biotextil Conventional enlargementTotal costs 380.00,00 € 680.00,00 €Saving in % 44%

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Profitability and Performance

If a performance increase of an existing plant is necessary, there is an alternative possibility to conventional enlargement of plant in realizing capacity increase with Cleartec® Biotextil of more than 100% wi-thout constructional measures. Beside the created virtual volume the refitting with Cleartec® Biotextil is significantly cheaper than conventional enlargement.

These advantages of Cleartec® Biotextil are confirmed with an example of use in the following.

Example of use 1:

Cost comparison of plant with target of capacity increase and same cleaning per-formance

ConditionsMunicipal WWTPVAB =2.000 m³Biomass (MLSS-Content): 4 kg/m³

Request75% capacity increase of biological stage and same cleaning performance

Profitability

An enlargement of secondary clarification isn’t considered in this calculation!


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Example of use 2:

The following is an illustration of a ca-pacity increase at a WWTP. In addition to suspended biomass the total biomass is increased of about 70 % by installing fixed bed in aeration basin. Increase of to-tal biomass results in a lower sludge load. At displayed example the aerobic sludge load is lowered by approx. 0,1 kg BOD/kg MLSS*d.

Due to low sludge load nitrification can proceed and on the basis of sessil biomass at the textile with considerably higher sludge age more nitrificants settle down. The biofilm ensures a high nitrification performance. That’s also the reason for a better year-round cleaning performance with regard to NH3 during low tempera-tures.



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Reduction of sludge load

Very good, stable NH3 elimination

Additional capacity by sessil biomass


References

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ARA Kelleramt, Schwitzerland

Komarno, Slovakia

Mukwonago, USA

Terrassa, Spain


References

19

Lahnstein, Germany

Council Bluffs, USA

Gorizia, Italy

Cleartec Water Management GmbHRuscheplatenstraße 1431137 Hildesheim, GermanyTel +49 (0) 5121 - 9138 800Fax +49 (0) 5121 - 9138 899 [email protected]

CLEARTECWater Management

water management jaeger group of companies ... · cleartec® biotextil wastewater treatment with...

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