General Features of the SBR Technology for WWTPs:

• Extremely effective biological treatment concept
• Perfectly useable for domestic and industrial wastewater
• Very space saving, compact plant design possible
• Modular structure of the treatment plant allows an easy extension
• Best process conditions for elimination of nitrogen and phosphorus
• Connection loads from 100 p.e. up to 100,000 p.e. (10 m³/d up to 50,000 m³/d)
• More than 200 reference plants already operating
• Perfect nitrification, denitrification and phosphorus removal possible

Decanting unit of the WWTP Amreya, Egypt

• Approved and reliable concept for biological treatment plants (activated sludge)
• Realization as combined arrangement (“combi-plant”) or independent placement of aeration tank (outer ring) and final clarifier (inner tank)
• For the aeration and mixing within the activated sludge basin the following technical solutions are available:
  • BSK®-surface aerator (bridge installation)
  • Membrane-aerators with additional submersed mixer
  • “HyperClassic®” or “Hyperjet”-systems with air dispersion
  • Rotating brushes with/ without additional submersed mixers
• Final clarifiers could be designed for gravity collecting (hopper shape) or mechanical scraping (flat bottom) of the sludge
• Hundreds of references since 1970 (e.g. General Motors “Opel”)

Wastewater Treatment Plant for General Motors (Opel AG)

• Patented biological treatment concept for high polluted industrial wastewater
• Combination of biological process, adsorption and filtration in one reactor
• By use of a specially produced activated carbon (HOK) the reactivating of the coke is performed by the biological process. No frequent replacement of the HOK-bed is required.
• Extremely simple, uncomplicated operation
• No sludge bulking or similar problems (well known from granty clarifiers) could occur
• Very low sludge production, good dewatering characteristics of the backwashed sludge
• Very low requirement for plant service (operation does not require skilled personnel)
• Also available as containerized plants for smaller capacities (up to 100-150 kg CSB/d)

HOK-WWTP of a big legware manufacturer in Morocco

• Containerized biologically operating wastewater treatment plants designed for smaller capacities (up to 1,000 p.e.). Preferably used for time limited operation or not stationary tasks, e.g. temporary hospitals, military camps (example: Wastewater Treatment Plant for the Camp Warehouse in Kabul, Afghanistan, for the ISAF) etc.
• Two step biological treatment plants for industrial wastewater (one of the reference plants: Central Hospital of Riad, Saudi Arabia)
• Nitrification and denitrification plants for effective biological treatment of wastewater with high nitrogen contents (reference plant: tannery "Ebelt" in Bentrup, Germany)
• Lagoon-concept for rural areas. Cost saving construction, preferably realized as naturally formed ponds with sealing foil for waterproof construction. High efficient aeration by pendulum membrane lines. Lagoon plants could be operated according to the SBR-concept or with final clarifier (continuous flow design)

Two step biological treatment plant for the famous brewery Rothaus AG (Germany)

• Compact high-performance reactor for the treatment of toxic and COD-polluted wastewater
• Patented process for a special wet-oxidation at an extremely low pressure of only 3 bar
• CSB reduction and change of toxic components into biologically treatable substances
• Elimination of color by application of ORCAN for textile wastewater
• Perfect solutions for treatment of high polluted partial flows
• Low operation costs caused by of hydrogen peroxide (H₂O₂) in a low pressure process
• Autotherm process, automatic operation, simple uncomplicated control
• Compared with conventional high-pressure technologies: safe and dangerous operation
• Extremely compact, space saving construction, uncomplicated installation for existing factories

Principle structure of an ORCAN treatment plant (turn-key station)

• Recycling plants for wastewater of hotels etc. originating in bathes, showers, washing dishes, laundry and similar low polluted systems
• Reuse of the treated wastewater for toilet water, car-wash, irrigation and cooling circuits
• Double filtration systems with special filter media for perfect polishing of the processed grey water
• Fully automatic run of the treatment plant
• Compact structure, easy to install even under cramped space conditions
• Operation reference: Kempinski Hotel in Beijing, China. Reuse for toilet flushing

(Greywater is also sometimes spelled: graywater, grey water or gray water and is also known as sullage)

Grey water recycling plant of the Kempinski Hotel in Beijing, China

• Turn-key plants for the treatment of manifold industrial wastewater effluents
• Neutralization-plants for basic and acid correction
• “Tailor-made” plants according to the individual project conditions
• On request: final biological stage for polishing of the pretreated wastewater (direct discharge into a river)
• Application of reliable brands for pumps, stirrers measuring systems and electrical control
• Tanks are strictly produced according to the WHG-regulations

pH-Correction system for a WWTP of home appliances company

• Cutting of coarse solids, which are e.g. parts of hotels wastewater. As experience shows, babies diapers, hygiene bindings, textiles etc. are usually disposed by toilet. These materials would clog the pumps, that is why they must be shredded
• The patented teeth-wheels are the heart of each muncher
• Several times hardened special steel guarantee long service lives and perfect cutting up effect
• Channel installation (e.g. channel model type A) for example in addition with disk rakes possible - for cutting up the screening from the inlet channel
• The installation into a pipe system is also possible with the muncher model TR

• Usable for solids-separation from wastewater (domestic and industrial)
• High separation rate by use of small slots or holes in the screen (3-8 mm)
• Automatic transport of the separated solids away from the screening zone
• Dewatering of the separated solids include/d
• Installation in concrete channels or in stainless steel casings possible
• Useable for indoor and outdoor installation (freeze proof)
• Different sizes for hydraulic loads up to 300 l/s
• Automatic, level depending operation. Controlled by local switch board

Double-Station for domestic wastewater (1,000 m³/h)

• Combination of fine-screen with sand-trap in one common stainless steel construction
• All parts are manufactured from stainless steel (AISI 304 or better)
• Perfect and money saving solution for flow rates up to 100 l/s
• Alternative 1: Separation of coarse material (> 3 mm) by use of fine screens with rotating spirals for solids removal
• Alternative 2: Separation of coarse material (> 3 mm) by use of step screens
• Spiral systems are including a dewatering zone for the solids.
• Step screens could be accomplished by a solids compactor
• Separation rate for sand up to 98 % (Ø 2.0 mm)
• Removal and transport of the settled sand by a combination of two spirals
• Hygienical storage of separated solids and sand by use of plastic bags
• Additional options: sand-wash installation and fat-separator
• Modification for outdoor installation possible (weather- and freeze proof)
• Automatic (and manual) operation by use of level sensors and PLC-control

Combined Station for 20 l/s

• For efficient separation of floating and settling solids
• Perfect use for pre-treatment of industrial wastewater
• Circular flotation systems according to the present design are the result of thousands of successful installations in nearly all industrial fields
• Completely constructed out of stainless steel
• Different sizes from Ø 1.5 m up to 22 m
• For hydraulic loads up to 2,500 m³/h
• For indoor or outdoor installations
• “All-in” delivery possible: including dosing systems for flocculants, incl. control panel and incl. connecting pipes and cables
• Delivery as assembly package for customer installation or turn-key performance by us

Flotation Plant in Lonza, Switzerland

• The perfect hydraulic design allows intensive mixing and high oxygen input
• Oxygen efficiency up to 2.5 kgO₂/kWh in domestic sewage (Alpha (α)-value = 0.9)
• Oxygen input capacity ranges up to 250 kgO₂/h
• Outer diameters of the turbines: 900 mm - 3,150 mm (6 sizes)
• Optional materials: GRP (glass-fibre reinforced plastic) or stainless steel (AISI 306/316 or upon customers request)
• Possible arrangements: on floating systems or on fixed bridges
• Variable speed for “mixing” (denitrification) and “aeration” (nitrification)
• Nearly maintenance-free gear drives (only one oil change every two years) available
• Standard design of the gear boxes for a life-time of more than 100,000 operating hours
• More than 2,000 already operating BSK®-Turbines (in co-operation with the Swiss inventor NORM A.M.C. AG) and his founder Josef Richard Kaelin
• Manufacturing of the GRP-turbines by our Korean partner SANGWON ENC
• Also available: The BSK®-Surface Aerator with integrated Solids-Macerator (made of stainless steel): The BSK®-Turbine type ZK

BSK® is a registered trademark of Biogest International® GmbH

BSK®-Turbine operating on a floating construction (SBR)

• Convincing alternative to surface aeration: patented submersed stirrer
• Fine bubble aeration due to mechanical air bubbles dispersion (coarse air bubbles input under the mixing unit)
• No danger of blockage, membrane-breaking or reduction of oxygen capacity
• “Mixing” (denitrification) and “Aeration” (nitrification) are possible as alternatives
• High ground speed prevents any settling at the tank bottom
• Oxygen input capacity: up to 120 kgO₂/h per unit
• Oxygen efficiency up to 2.5 kgO₂/kWh. Alpha (α)-value ca. 0.9 (domestic wastewater)
• Nearly maintenance-free gear-drives (only one oil change every year)

“HyperClassic®”-stirring and aeration system

• Ideal mixing and aeration system for small-sized wastewater treatment plants
• No additional air blower required - self suction of air
• Completely made of stainless steel (AISI 304 or better)
• No danger of blockage or plaiting of fibre-solids
• Gear-drive requires a minimum of maintenance (only one oil-change every two years)
• Low speed for “Mixing” (denitrification)
• High speed for “Aeration” (nitrification)
• Outstanding high service life of the gear-box bearings (> 150,000 h)
• Perfect installation for buffer tanks and sludge storage tanks (mixing and homogenisation)
• No submerged wear parts

“Hyperjet®” - Self-Suction Aerator and Mixer

• Membrane aeration is the traditional way for oxygen input for biological treatment plants
• Biogest International developed a combined equipment for activated sludge tanks, which contains special membrane aerators (located at the tank bottom) and one or more stirrers (system code: MBR aeration technology) for perfect performance of nitrification and denitrification
• Membrane aerators are available as pipes, circular discs or hoses (with stainless steel frame). The final mode of equipment will be decided upon the project conditions (tank shape, wastewater analysis etc.)
• The stirrers are time-tested constructions, preferably designed as HyperClassic®-mixers but also as vertically or horizontally installed propellers
• Our MBR equipment (incl. first-class blowers) delivers high oxygen transfer rates, a proper Alpha (α)-factor (> 0.7) and efficiency rates of not less than 3.0 kgO₂/kWh (standard cond.)

Fine-bubble aeration system - Kardjali, Bulgaria

1. Task and Objective

   In contrary to conventional wastewater treatment plants treated wastewater resulting from sequenced batch reactors (SBR) cannot be discharged by use of a traditional overflow weir. Typical for SB-reactors is the fact that purified wastewater must be discharged by moving overflow constructions, which are following the descending water level.
   The crucial point of all decanting systems is to avoid the entrance of floated and settled sludge. Moreover, the operation of decanting systems must be extremely reliable due to the fact that it is one of the most important technical components of SBR-wastewater treatment systems.

2. Design-Variations of Clear Water Discharge Systems

   The increasing application of SBR-treatment plants motivated several manufacturers to develop systems for discharge of treated wastewater – resulting in very different constructions and methods. The simplest variant is a fixed pipe equipped with an electrical valve being installed next to the min. water level – combined with plenty of disadvantages: only after the sludge is completely settled, the valve could be opened. Moreover, such a fixed discharge-position does not allow a flexible adaption of the discharge level to changing sludge volumes
   More advantages are provided by floating or moving decanting systems. However, they must be designed in such a way that the advantages are not eliminated by complicated trouble-prone constructions

3. Our Solution: The BSK®-Decanter

   The focus of our development was the target to create a discharge system for treated wastewater, which avoids the well known disadvantages of effluent systems. More than 100 of worldwide installed BSK®-decanters are proving that our decanter-construction represents an outstanding development, which convinces designers and operators with following features:

   • Completely made of stainless steel
   • Maintenance-free, corrosion-proof components
   • Dry mounted robust drive system with comfortable access
   • No entrance of floating sludge
   • No whirl-up of settled sludge
   • Variable hydraulic discharge capacities
   • Extremely low operation costs
   • Reasonable investment costs

4. Brief Description of Operations:

   1. The stainless steel pipe construction equipped with a maintenance-free rotating submersed twist is moved down to the water level by an electrically driven winch
   2. Specially designed openings in the horizontal inlet pipe guarantee a symmetrical entrance of treated wastewater – without turbulences
   3. Floating sludge is successfully prevented to enter the inlet pipe by a specifically designed baffle
   4. A step-by-step downwards movement will be stopped at a safe distance to the settled sludge level – controlled by limit switches (or sludge sensors)
   5. As soon as the minimum water level is reached, the BSK®-decanter is pulled up into the “parking position”
   6. In this parking position, the BSK®-decanter is offering an emergency overflow (automatically generating an alarm signal)

   The up and down movement of the BSK®-decanter is reliably controlled by robust limit switches (being part of the winch-drive). Two duty and two stand-by switches guarantee a perfect reliability.

5. Decanter-Types and Hydraulic Capacities

   Seven different sizes of BSK®-decanters are offered. Based on a standard application-case (TWL = 5.0 m / LWL = 3.0 m), following capacities are resulting:

   Type Code

   Capacity Q [m³/h]

   
   

   BSK® D100

   130

   BSK® D150

   320

   BSK® D200

   570

   BSK® D250

   790

   BSK® D300

   1.180

   BSK® D350

   1.650

   BSK® D400

   2.160
   
   

   Each application of BSK®-decanters will be individually designed in cooperation with our customer – with the target to find an optimized technical and commercial solution.

6. … some more important details

   BSK®-clear water decanters are individually customized with respect to all following subjects:

   • Specification of material (stainless steel AISI 304 / 316 or even better)
   • Kind of operation (overflow- or siphon-hydraulic)
   • Electrical network conditions (voltage, frequency etc.)
   • Deep temperature conditions (isolated cover including heating system for electrical winch)
   • Control systems (level sensor, sludge level detection etc.)
   • Scope of supply / limits of delivery

BSK®-decanters are also offered as a special modified type for discharge of turbid water i.e. from sludge storage tanks – operating automatically or manually.
Our engineers are eager to consult our customers in order to find a proper solution for the application of BSK®-decanters.

BSK®-Decanter | Decanting Systems

• Effluent Discharge Systems (Decanters) for SB-Reactors:
  • Option 1: simple, fixed installed outlet pipe with electrical valve
  • Option 2 (BSK®-decanter): movable T-pipe with submersed elbow-twist driven by a dry mounted electrical winch
  • Option 3: submersible pump in fixed or adjustable position
• Our BSK®-decanters also can be used as sludge water discharge systems, to simply remove the turbid water which results from static sludge thickening in sludge storage tanks.

BSK® is a registered trademark of Biogest International® GmbH

BSK®-Decanter of the wastewater treatment plant of the city Kaisten, Switzerland. Plant load: 8,600 m³/d

• Some applications require the use of equipment for dosing various products. Again, we closely cooperate with leading manufacturers to ensure the best combination of specific equipment and chemicals needed for each application.
• The dosage may be necessary during the biological stage, the sludge treatment or in the discharge area of the wastewater treatment plant.
  Some examples:
  • Precipitation, coagulation and formation of flocs: the commonly used substance is iron chloride (FeCl₃) or similar for effective removal of phosphates, reducing the index of the sludge or floating sludge removal.
  • Dosage of substances to combat smell from sewage plants, pumping stations or landfills, mostly caused by hydrogen sulfide (H₂S).
  • Dosing units for the production of aqueous solutions of polymers with organic flocculants for sludge treatment. They are necessary in order to streamline the sludge dewatering. The Polymer solution can be obtained by the use of a powder polymer concentrate.
  • Dosage units for liquid chlorine to disinfect the treated effluent. Dosing of the disinfectant is automatically controlled depending on the amount of treated wastewater.

Chlorine and precipitating agents Dosing Station for a Municipal wastewater treatment plant (600 p.e.)

1. Sludge Thickening Centrifuges
   • High performance centrifuges of different brands incl. energy recycling
   • Individual selection of the best technology according to the project conditions
   • Delivery with all required components like basic frames, sludge transport systems, polymer processing plants, control panel etc.
2. Sludge Thickening Drums
   • For easy and economic concentration of excess sludge (resulting from activated sludge systems)
   • Completely constructed out of stainless steel (AISI 304 or better)
   • Automatic operation by PLC-control
   • Including sludge-reactor, capsuled rotating drum, effluent storage tank and high pressure pump for spray system
   • Concentration capacity up to 10 % dry matter
   • Variable rotating speed (adjustable gear drive)
   • For sludge flows up to 100 m³/h
   • Automatically operating polymer processing plant available as optional component

Sludge thickening centrifuge of the WWTP Kardzhali, Bulgaria

1. Sludge Dewatering Systems / Centrifuges
   • High performance centrifuges of different brands for capacities of up to 30 m³/h (up to 1,500 kg DS/d) incl. energy recycling
   • Individual selection of the best technology according to the project conditions
   • Delivery with all required components like basic frames, sludge transport systems, polymer processing plants, control panel etc.
2. Filter Presses
   • Reliable, solid and stable construction, based on the experience with hundreds of operating plants. Produced in the factory of our partner-company
   • Plate sizes between 400 and 1,600 mm
   • Manual and automatic operation upon request
   • Delivery with all required components like basic frames, sludge transport systems, polymer processing plants, control panel etc.

Sludge dewatering centrifuge with transport screw for dewatered sludge in Kardzhali, Bulgaria

• Sludge water discharge system to remove the surface water from the sludge storage tank
• Height adjustable decanter construction made of stainless steel, identically designed to the BSK® clear water decanters for the SB-Reactors
• The realization with an electrical hoist or with a hand winch are possible
• The use of an electrical rope winch permits the fully automatic discharge of the sludge water
• The turbid water is transported normally back into the inlet pumping station

BSK® is a registered trademark of Biogest International® GmbH

Sludge water discharge decanters with manual winches. This picture shows 2 BSK®-Decanters in 2 adjacent sludge storage tanks.

• For efficient separation of floating and settling solids
• Perfect use for pre-treatment of industrial wastewater
• Circular flotation systems according to the present design are the result of thousands of successful installations in nearly all industrial fields
• Completely constructed out of stainless steel
• Different sizes from Ø 1.5 m up to 22 m
• For hydraulic loads up to 2,500 m³/h
• For indoor or outdoor installations
• “All-in” delivery possible: including dosing systems for flocculants, incl. control panel and incl. connecting pipes and cables
• Delivery as assembly package for customers installation or turn-key performance by us

Flotation Plant in Lonza, Switzerland

• The aim of sludge dewatering is to win a high percentage of dry matter. For this purpose, a high-performance centrifuge can be used in the sewage treatment plant, which has been developed specifically for dewatering of sludge. However, the solid-liquid separation is not very successful without the addition of separation aids, because there exit strong bonding forces between the water and the deposited solids. The addition of a so-called “polyelectrolyte” dissolves these bonding forces and leads to an association of the solid particles of the sludge to stable flakes and a physical separation of the liquid and the solids takes place. This separation leads within the centrifuge to a spatial separation of the considerable heavier sludge flakes (with respect to its volumetric weight) by centrifugal forces. Consequently, the carrier liquid (= sludge-water) leaves the dewatering system by the overflow of the centrifuge. The concentrated solids within the centrifuge are discharged by use of the clearing worm out of the casing area into a screw conveyor.
• The sludge has different physical properties depending on the composition of the wastewater (influence of industry, water quality etc.) So the right choice of a polyelectrolyte is a task which needs to be resolved within the first months of operation of a sewage plant. By adopting various polyelectrolyte (cationic charge, anionic charge, combined charge etc.) on the laboratory scale, the flocculation and phase separation can be determined very accurately. The seemingly most suitable polyelectrolyte is then tested for practical use, and finally used for further sludge dewatering (at actual suitability).
• The BSK® POLY polymer dosing stations which are developed and produced in our facilities, have the task of preparing the delivered concentrated product for application. Then the polymer is available in a so-called “working solution” and can be mixed with the sludge. By use of the BSK® POLY polymer dosing station, a fully automatic and required production of the solution is achieved.
• The automatic sequence of all processes within the dosing system is monitored and controlled by an integrated control cabinet. With the help of a touch panel, it is possible to modify certain operating parameters in order to respond flexibly to the procedural conditions.
• In addition to the polymer concentrate, also a granulated powder can be used. To this end, the polymer-dosing station can be equipped with a so-called “dry material feeder”.
• Possible basic components of a BSK® POLY polymer dosing are:
  • Base container with one or more chambers
  • Concentrate pump
  • Dry material feeder for powder polymer
  • Stirrer
  • Dosing pump
  • Measurement equipment
  • Control cabinet with PLC, for example Siemens

BSK® is a registered trademark of Biogest International® GmbH

BSK®-POLY polymer dosing system during operation

• The central control of operation sequencing takes place with the help of a switchgear cabinet, which has an programmable logic control (PLC). By changeable operating parameters the personnel of the sewage purification plant can consider different operational situations and can select for example between a single-stage and a multi-stage operation
• Partial or also entire operation of the plant can be fully automatic implemented
• The individual limit values, e.g. for the oxygen or the period of time of the nitrification and denitrification phases, are adjusted at the operating panel of the PLC, e.g. a SIMATIC panel by Siemens
• The visualization and archiving of the individual characteristic values can be realized with a screen writer, e.g. the (paperless) Memograph by Endress+Hauser

Moduls of a PLC

• Own planning, manufacturing and assembly of the control cabinets and local control boxes for the completion of our wastewater treatment plants in accordance with the usual VDE guidelines
• The used components of considerable manufacturers, e.g. Siemens, Kraus & Naimer, Moeller, Endress + Hauser etc. are purposefully selected according to the case of application and guarantee a high availability and working reliability
• Desires of the customer and requirements of the client for the control, measuring and automatic control are naturally considered
• Our switchgear cabinets can be equipped for example with mimic diagrams for process visualization or with touch panels
• We complete our purification plants with our own control panel manufacturing. It is coordinated to the respective tasks and equipped with PC control and control system and connections to remote tele-control systems if desired

Manufacturing line of our control panels