MBBR: A Small Solution with Big Results

In a crowded marketplace, moving bed biofilm reactor (MBBR) systems stand out for their practicality, usability and cost-effectiveness. In this blog, we detail why this small footprint wastewater treatment solution is so effective for existing facilities, as well as new sites.

There are several wastewater treatment systems designed to help firms deal with wastewater and sewage. Despite the competition, few technologies can offer the same combination of benefits as a MBBR system for both municipal and industrial applications. MBBR technology is a highly effective biological treatment that provides a simple-to-operate, compact solution. As a result, the system is the perfect fit for both new installations and the upgrade or expansion of existing sites, especially where space is limited. What’s more, as MBBR systems have the ability to cope with varying loads, they are suitable for use within plants that experience peaks in treatment loads or tight discharge limits.

What is a MBBR System?

MBBR is a wastewater treatment technology that uses specially designed plastic carriers, or biofilm carrier elements, to grow beneficial bacteria that clean water. These carriers are made from polyethylene and are designed to provide a large protected surface for the bacteria culture that facilitates the removal of biochemical oxygen demand (BOD), ammonia and nitrogen. To achieve this, the carrier elements, which have a density slightly below that of water, are kept suspended in the water by air from the diffusers in the aerobic reactors and by means of a mixer in the anoxic reactors. Thanks to this approach, MBBR systems can perform effectively across a spectrum of applications, including use as a sole bio-treatment, a pre-treatment and a post-treatment. 

What are the MBBR Implementation Options?

 From our experience, MBBR systems can deliver significant benefits on existing treatment facilities, which need extra capacity. This is because MBBR systems can be used as a high-loading system in front of an existing biological treatment. For example, if an existing facility needs to respond to tighter discharge limits, then installing a MBBR system can be a great solution. On such projects, a MBBR system can help facilities to take the load off an existing site, allowing the new, higher level of treatment to be achieved or creating more treatment capacity. We recently accomplished this for a client; read the case study here.

At a glance, MBBR systems can be applied as:

• Primary biological treatment
• Pre-treatment enhancement
• Post-treatment optimisation
• Retrofitted solutions for existing facilities
  

Another example of this process benefiting a client was at Cudworth Sewage Treatment Works (CSTW). In line with its asset management plan, the facility needed to increase capacity to serve a 2025 population equivalent of 10,693. Similarly, the site needed to treat its wastewater to a more stringent discharge quality. The long-term performance and cost-effectiveness of our MBBR system made it the most suitable choice. To this end, we installed an AnoxKaldnes™ MBBR process for residual BOD removal and nitrification.

Immediately after the system’s installation, performance on site improved. Thanks to the MBBR system, the secondary effluent from the existing humus tanks can now be pumped into a splitter box to the 2 MBBR streams, followed by the discfilter filtration units and discharged to the River Dearne via the existing outfall. Unlike before, the wastewater is virtually ammonia-free, which means it meets the Environment Agency’s new regulations on water quality.

The Need for a Small Footprint

As well as their efficiency, MBBR systems provide a small footprint solution, which makes them easier to fit on new or existing facilities. Additionally, MBBR systems are the ideal solution for facilities that need to increase capacity but can’t expand the site’s footprint. This was demonstrated during work at a fish farming facility called Marine Harvest Dalsfjord in Norway. The site needed to build two separate recirculating aquaculture systems (RAS) plants, but had limited space. RAS plants, which are increasingly common across fish farming, use indoor tanks to rear high densities of fish. The system creates a more controlled environment for fish to grow and can help to reduce water consumption when compared to traditional, open ponds. 

Fortunately, our team was able to help, designing both RAS plants in an extremely compact manner. To this end, the first RAS plant was able to treat 2,850 m3 of water in a footprint of just 200 m2. Similarly, the second facility was built with a capacity to provide 2,000 kg per day of feeding to the fish, with a total hydraulic capacity of 2,400 m3 every hour despite a footprint of less than 250 m2. 

Are MBBR Systems Easy to Use?

Some companies feel uneasy specifying water treatment systems that they feel unfamiliar with. Fortunately, MBBR systems are inherently easy to operate. From our experience, on-site staff tend to learn how to use the system quickly. However, we are also on hand to provide technical support and guidance should an issue occur. Similarly, when compared to alternative approaches, MBBR represents a cost-effective solution, especially when used as a pre-treatment upstream of an existing secondary treatment process such as activated sludge plant or trickling filters. The technology is quick and easy to install, offering plug and play function, which reduces on-site construction time. Furthermore, through their lifecycle, MBBR systems require minimal maintenance. 

With over 1,100 successful installations spanning both municipal and industrial applications, Veolia Water Technologies UK stands as a world leader in MBBR technology. Our comprehensive solutions include the standard MBBR package system featuring AnoxKaldnes™ media, and specialised treatments like the ANITA™ Mox process for high-ammonia streams.

Drawing on nearly 40 years of expertise since the technology's inception, we've continuously evolved our offerings through extensive R&D, developing innovations such as patented alternating flow configurations and customisable post-treatment systems. Whether you need a standard prefabricated package or a bespoke solution, our proven track record and deep understanding of both municipal and industrial applications ensure we can deliver the perfect MBBR system for your specific requirements. Contact our experts today to discover how our MBBR solutions can transform your wastewater treatment operations.

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