How Our Dual Stage Biofilters Work

How Our Dual Stage Biofilters Work

TECHNOLOGY DESCRIPTION

vitaAER dual stage biofilters combine a bio-trickling filter with a biofilter to achieve comprehensive odour and contaminant removal. The first stage utilizes the bio-trickling process to eliminate high concentrations of H₂S, while the second stage biofilter targets residual non-soluble odours, organic sulphur compounds and VOCs.

The bio-trickling filter employs synthetic media, whereas inorganic media is used in the biofilter stage. In the bio-trickling filter, foul air is introduced at the bottom of the reactor vessel by a fan, and water is evenly distributed from the top by a recirculation pump. This maintains a moist environment conducive to gas-liquid phase transfer, supporting predominantly autotrophic microbes and flushing out by-products.

The synthetic media provides a surface for biofilm attachment and gas-film contact, where most odorants are biodegraded. Some odorants are also removed by microorganisms suspended in the liquid effluent. Controlled recycling of the liquid effluent ensures microbe re-seeding, effective scouring of salts and metabolites, accurate nutrient addition, better pH control, and reduced water usage.

The second stage biofilter effectively removes remaining odours and contaminants. The inorganic media is pH-buffered and nutrient-enhanced to create a pH-neutral environment ideal for heterotrophic microbes. Dead biomass, salts, and other contaminants are periodically flushed out by a timer-controlled irrigation system, ensuring optimal performance and maintenance of the biofilter.

CONFIGURATION TO CUSTOMER NEEDS

Flexible design allows for housing of our biofilter technology in cylindrical or rectangular vessels to match site conditions and customer preferences.

MATERIALS

Reactor vessels are fabricated from polypropylene, fibreglass-reinforced plastic or concrete for large systems (airflows>20000m³/h). Plastic vessels are corrosion resistant and designed for a 20-year lifespan. Concrete vessels are lined with HDPE anchor knob sheeting to protect against sulphuric acid attack. All other components are acid and corrosion resistant.

RECIRCULATION PUMPS

Recirculation pumps are constructed from acid-resistant materials and selected for reliable operation and low maintenance. Pumps are self- priming.

PERMANENT MEDIA

Our bio-trickling filter (synthetic) and biofilter (inorganic) medias are selected for their large surface area/volume ratios, water storage capacities, pore sizes, low pressure drops, structural integrity and chemical/biological resistance. Our medias are guaranteed to last for a minimum period of 10 years.

NUTRIENT DOSING SYSTEM

Where treated effluent is not available nutrient containing nitrogen, phosphorus, potassium and trace elements are added to sustain biological activity.

ODOUR VARIABILITY

Our dual stage biofilters are engineered to cope with variable odour concentrations ensuring constant and reliable odour removal.

SIMPLE & RELIABLE OPERATION

There are no complicated control systems or sensors. PLC operation is not required. Airflow, water recirculation and irrigation rates are set at time of commissioning. Nutrients (where required) are replenished monthly.

CONTROL PANEL

Control panels are locally designed and constructed to local codes and individual customer specifications. All components are locally available for quick and easy replacement.

LOCAL CONTENT

Designed and manufactured (locally) in collaboration with our local and international technology partners.

How Our Bio-Trickling Filters Work

How Our Bio-Trickling Filters Work

TECHNOLOGY DESCRIPTION

vitaAER bio-trickling filters consist of polypropylene (PP), glass reinforced plastic (GRP) or concrete reactor vessels housing synthetic media to support microbial growth. Foul air supplied by a fan enters at the bottom of the reactor vessel with water supplied by a recirculation pump and evenly distributed from the top to maintain a moist environment for gas-liquid phase transfer, to support microbial growth and to flush out dead bio-mass and salts.

CONTROLLED LIQUID RECYCLING

Controlled recycling of the liquid guarantees constant and reliable odour removal performance:

  • pH can be maintained within ideal parameters
  • ensures constant microbe reseeding
  • constant scouring of media prevents anaerobic zones from developing salts
  • metabolites and dead bio-mass are flushed out
  • allows controlled nutrient addition (if needed)
  • allows better temperature control
  • saves water

EVEN AIRFLOW & EFFICIENT MASS TRANSFER

Air and water flows are countercurrent to ensure even air distribution and improved mass transfer.

CONFIGURATION TO CUSTOMER NEEDS

Flexible design allows for housing of bio-trickling filter technology in cylindrical or rectangular vessels to match site conditions and customer preferences.

VESSEL MATERIALS

Vessels are fabricated from polypropylene, glass reinforced plastic or concrete for large systems (airflows>20000m³/h). Plastic vessels are corrosion resistant and designed for a 20-year lifespan. Concrete vessels are lined with HDPE anchor knob sheeting to protect against sulphuric acid attack.

RECIRCULATION PUMPS

Recirculation pumps are constructed from acid-resistant materials and selected for reliable operation and low maintenance. 

MEDIA

Our engineered synthetic media is selected for its large surface area/volume ratio, water storage capacity, pore size, low pressure drop, structural integrity, 10-year lifespan and chemical/biological resistance. Our media is guaranteed to last for a minimum period of 10 years.

NUTRIENT DOSING

Where treated effluent is not available nutrient containing nitrogen, phosphorus, potassium and trace elements are added to sustain biological activity.

ODOUR VARIABILITY

vitaAER bio-trickling filters are engineered to cope with variable odour concentrations ensuring constant and reliable odour removal.

SIMPLE & RELIABLE OPERATION

There are no complicated control systems or sensors. PLC operation is not required. Airflow and water recirculation rates are set at time of commissioning. Nutrients (where required) are replenished monthly. Irrigation water pH is maintained between 1-3 by continuously bleeding a small volume of process water.

CONTROL PANELS

Control panels are locally designed and constructed to local codes and individual customer specifications. All components are locally available for quick and easy replacement.

LOCAL CONTENT

Designed and manufactured (locally) in collaboration with our local and international technology partners.

Odour Control at Sewage Pump Stations

Odour Control at Sewage Pump Stations

Since 1999, vitaAER and its technology partners have designed, manufactured, supplied, installed and commissioned in excess of a hundred biological, chemical and physical odour control systems throughout South and Southern Africa.

Odour control technologies for treating municipal wastewater odours are typically classified as biological (bio-trickling filters, biofilters and bioscrubbers), chemical (dry scrubbers and wet scrubbers) or physical (carbon adsorbers and photo-ionisation) systems.

Each of these systems has strengths and weaknesses and selecting the appropriate technology depends on the details of the application and the specific needs of the customer.

Selecting an appropriate odour control technology and sizing an odour control system for a particular application require careful consideration of the following factors:

  1. Physical and chemical characteristics of the odours
  2. Odour concentrations
  3. Required odour removal efficiency
  4. Required foul air extraction rate
  5. Available space
  6. Water availability
  7. Effluent discharge requirements
  8. Electrical requirements
  9. Maintenance requirements and available resources
  10. Life cycle costs

Odour control systems are sized based on foul air extraction rates, odour mass loading and required odour removal performance. The foul air extraction (air treatment rate) is based on the peak air displacement rate (liters/s or m³/h) from a pump station wet well during filling plus a safety factor (i.e. 20-30%). Odour concentrations are determined by recording H₂S concentrations (used as a signature odour) with loggers over a time-period (typically 7 to 14 days under worst case conditions).

Based on our experience and drawing on worldwide industry know-how we believe that bio-trickling filters and dry scrubbers are the most appropriate technologies for treating odours typically associated with sewage pump stations.

Bio-trickling filters have the lowest life cycle cost of all available technologies and have the least impact on the environment. In addition, they require relatively limited maintenance and can operate without operator intervention for extended periods. The economic advantage increases as mass loadings and the system size increase due to economies of scale.

For smaller/lower mass loading applications, dry scrubbers are ideal because they are compact and virtually maintenance-free. Dry scrubbers can run for years without any maintenance and require no operator intervention. However, dry scrubbers become less economical as mass loadings and the system size increase.

Although vitaAER also offers wet scrubbers, carbon adsorbers and photo-ionisation systems, the disadvantages associated with these systems make them mostly unsuitable for treatment of sewage pump station odours. Wet scrubbers require continuous replenishment and dosing of hazardous chemicals and require constant maintenance. Carbon adsorbers are by far the most expensive of all technologies due to the cost of regular carbon replacement. Photo-ionisation systems are also expensive to operate due to the cost of replacing UV-lamps and catalyst every 12 to 18 months.

For effective and economic odour control at sewage pump stations vitaAER therefor recommends bio-trickling filters for pump stations where average H₂S concentrations exceed 15 ppm and dry scrubbers for treating lower average H₂S concentrations.

Successful treatment of wastewater odour

Successful treatment of wastewater odour

Increasingly, odour complaints feature on management agendas at wastewater treatment facilities.

There are a number of reasons for this. As urban areas expand, distances between municipal wastewater treatment plants and neighbours decrease. The capacities of wastewater treatment plants have not kept up with increased demand and plants are routinely overloaded. Collection systems have been widened to include growing towns and cities, resulting in longer sewer lines, causing increased septicity. The collection, conveyance and treatment of municipal wastewater present a number of challenges that must be managed in order to minimise the impact on neighbours. Controlling odours is one of these management challenges.

Aerobic wastewater contains a variety of odour-causing compounds such as organic acids, esters, alcohols, aldehydes as well as indole and skatole. Also, when oxygen is consumed in the wastewater, due to extended detention times and high organic loading, anaerobic areas develop and release odours at a much greater rate. Hydrogen sulphide and other organic sulphides such as methyl mercaptan (MM), dimothyl sulphide (DMS), and dimethyl disulphide (DMDS) have very low detection thresholds and can lead to health and safety issues.

Characteristics of odour

A general understanding of odour and the properties of odorants and their perception is useful for understanding the implications for odour abatement technologies.

Airstreams can contain spectrums of odorants each with their own unique characteristics.

The key parameters or characteristics of interest for odour control systems are:

  • water solubility
  • molecular weight
  • molecular structure
  • vapour pressure
  • odour detection threshold.

These parameters all have a direct impact on the availability and degradability of the compounds, as well as their potential to cause an off-site negative impact upon surrounding communities.

The major groups of odorants that require consideration are:

  • hydrogen sulphide
  • organic sulphides
  • ammonia and nitrogen compounds
  • VOCs.

Hydrogen sulphide

Hydrogen sulphide is generated through anaerobic decomposition of the organic material contained within the wastewater. It is a colourless, toxic gas that has a characteristic odour of rotting eggs. Hydrogen sulphide is heavier than air, contributes to corrosion of infrastructure and can be immediately dangerous to life and health above concentrations of 100 ppmv. It is soluble in water and is readily biodegradable in biological systems. The odour detection is reported to be as low as 5 ppb.

Organic sulphides

These complex molecules are also produced as a by-product of anaerobic decomposition of organic materials present in the wastewater. A diverse group of higher molecular weight compounds such as methyl mercaptan, ethyl mercaptan, dimethyl disulphide, and dimethyl sulphide are garnering more and more attention for ensuring all odours are effectively contained and treated at wastewater treatment plants. These compounds have a wide variety of solubilities and characteristic odours ranging from rancid, skunk-like to decayed cabbage. These compounds, other than methyl mercaptan, tend to be more recalcitrant to biodegration and have very low detection thresholds. Detection thresholds can be as low as 0.03 ppb.

Ammonia and nitrogen compounds

As organic material in wastewater is degraded, ammonia, amines and other nitrogen-bearing compounds will be released. These compounds tend to be highly water soluble and readily biodegradable.

VOCs

There are many other potential odour contributors that can be released from treatment processes. These vary greatly in composition and their impact on the corresponding selection of abatement equipment. Organic acids such as aceticand butyric acid are readily biodegradable. Aldehydes, ketones and aliphatics may also be present in the airstream. The composition and concentration of these components are a function of the raw sewage sources. While these compounds are typically overpowered by the sulphur-bearing, and to a lesser extent, nitrogen-bearing compounds present in the air stream, they are becoming increasingly more important as consideration for optimised odour control applications in sensitised urban environments.

Odour emissions for individual wastewater unit treatment processes

The characteristics of the odours that are emitted from the various types of wastewater unit treatment processes vary considerably in terms of constituents and concentrations.

Wastewater treatment processes can be classified into three main segments: collection, liquid-phase treatment and residuals or biosolids treatment. While biological technologies are robust and flexible, not every application can be addressed appropriately with a single technology. Knowing when and how to use a technology is a critical element in the successful implementation of an odour control strategy.

Odour treatment technologies used to control odours rely on the following processes: biological, chemical, electro/chemical, thermal or physical and selection depends on the following factors:

  • chemical and physical characteristics of odorants
  • required removal performance
  • space available
  • maintenance requirements
  • capital cost
  • life-cycle cost
  • influent concentrations
  • variability of loading.

Biological systems

With biological systems, micro-organisms are used to biodegrade odorants into simple compounds. The odorants are first absorbed into a water film that contains microbes. The microbes metabolise the pollutants in order to obtain energy and nutrients. Perhaps, because this process is similar to the process used to treat wastewater, biological filters are outstripping competing technologies on municipal wastewater treatment plants.

Biological systems either employ organic or inorganic media and are divided into biotrickling filters, biofilters or combinations thereof. Systems can either be open or closed. A closed system is preferable because of improved control of the factors affecting performance.

Modern biological systems use inorganic media because the media usually does not require replacement and lower pressure losses mean savings in energy consumption. Biological systems can treat airflows with variable odorant loadings. Biological systems require water sup- ply and drainage points.

Physical process

The most common example is a carbon adsorber where foul air is passed through a virgin or impregnated carbon bed. The odorous substance is physically captured in or on the carbon. Advantages of carbon adsorption are its ability to capture a wide range of odorants and low energy requirements. Disadvantages are high running costs because the carbon has to be replaced (especially in case of high odorant loadings), humid air can affect the adsorption process when the media is saturated, breakthrough is sudden and the spent media is toxic and has to disposed of in landfills for hazardous materials. Carbon is sometimes used as the final stage in a multi-stage odour control system to remove traces of remaining odorants.

Thermal systems

Thermal energy is used to oxidise odorants. Although thermal systems are effective, the high energy costs result in very few being found in wastewater treatment plants.

Chemical systems

The most widely used examples for treatment of wastewater odours are wet scrubbers. Odorants are dissolved in water that usually contains a reactant. The major advantage of wet scrubbers is that a short retention time results in a compact footprint. Negatives are an inability to cope with fluctuating odorant loadings and the effluent is toxic where oxidants are used. With airstreams where multiple odorants are present, a series of scrubbing vessels using different reactants and operating at different pH levels are required.

Electrochemical systems

Ultraviolet or photocatalytic oxidation is used to convert odorants to a non-odorous state. With photocatalytic oxidation, UV lamps are used in conjunction with a catalyst surface. The catalyst surface becomes active in the presence of UV light. The odorant is adsorbed onto the catalyst surface and then decomposed similar to catalytic oxidation. Advantages are a small footprint, no water or drain is required, low maintenance requirements and low energy consumption. However, the UV lamps and catalyst must be replaced at regular intervals.

How Our Dry Scrubbers Work

How Our Dry Scrubbers Work

TECHNOLOGY DESCRIPTION

Our dry scrubbers trap odours on/in solid porous media in a 3-stage process. In the first stage H₂S reacts with ferric oxide. Remaining odours (organic sulphur compounds and others) are then oxidised in a secondary stage with stabilised chlorine dioxide. Traces of residual odours are finally removed with activated carbon. The media is housed in multi-chambered vessels fabricated from corrosion resistant polypropylene materials.

Each dual chambered vessel consists of an inlet chamber, lower air diffusion plate, lower oxidising media chamber, middle air neutral diffusion media, upper polishing media chamber and clean air outlet vent. The system is completed by interconnecting ductwork, flow balancing valves and air extracting fans. The extraction fan creates a partial vacuum via connecting ductwork to a covered odour source to avoid odour leakage. Foul air is pulled into the inlet chamber and diffused via the lower diffuser, which is designed to maximise its distribution across the surface of the media. The air is then drawn upwards through the oxidising chamber, which houses three media types.

VESSEL MATERIALS

Vessels are fabricated from polypropylene. Vessels are corrosion resistant and designed for a 20-year lifespan. All other components are manufactured from either 316 Stainless Steel or plastic to ensure corrosion resistance.

MEDIA MIX

Iron oxide is used as a primary treatment to remove the bulk of H₂S. The second stage media is chlorine dioxide which instantly oxidises a broad spectrum of odours followed by activated carbon to remove traces of any remaining odours. Sulphides are oxidised to sulphates, mercaptans to sulphates and sulphonic acids and amines to carboxylic acids. The products of the reactions are odourless and environmentally sound. No chlorinated organics are formed.

SIMPLE & RELIABLE OPERATION

There are no complicated control systems or sensors. PLC operation is not required. Airflow is set and locked at time of commissioning.

MINIMAL MAINTENANCE

Of all odour control plants dry scrubbers require the least maintenance. Systems are designed for media to last 3 years and fans must be replaced every 5 years. There are no moving/electrical components other than the fan.

CUSTOMISED SYSTEM CONFIGURATION

Flexible and sometimes modular design allows for housing media in cylindrical or rectangular vessels to suit customer preferences and site conditions.

SIMPLE CONTROLS

Simple fan on/off operation is standard.

ENVIRONMENT-FRIENDLY

No water usage, zero effluent and minimum energy requirements make this the most environment-friendly odour control system. Spent media can be used as compost.

LOCAL CONTENT

Designed and manufactured (locally) in collaboration with our local and international technology partners.