MBBR (Moving Bed Biofilm Reactor)
Efficient MBBR (Moving Bed Biofilm Reactor) Solutions for Industrial Wastewater Treatment
The MBBR process is a highly adaptable aerobic treatment method, well-suited to the variability in industrial wastewater. It typically offers a small footprint and can be designed to focus on the removal of lower percentages of organics and nutrients, rather than achieving full conversion like other systems. This makes it an ideal biological treatment solution for discharging to the sewer when primary treatment alone is insufficient.
Some of the main benefits of MBBR technology are:
- Compact Design & Reduced Footprint: The high concentration of biomass attached to the media within the aeration zone allows for smaller tank sizes and reduced overall system footprint, making it ideal for space-constrained applications.
- Flexible Organic Removal: MBBR systems are adaptable for both partial and full organic removal. The partial removal is especially beneficial in trade waste or sewer discharge scenarios, where primary treatment alone may not meet discharge limits.
- Efficient Nutrient Removal: MBBR technology enables effective nutrient removal through the integration of pre-anoxic zones and mixed liquor return (MLR), optimising nitrogen and phosphorus removal.
- Upgrading Capability: Conventional activated sludge plants can be efficiently upgraded to the MBBR process. This upgrade increases treatment capacity for larger flows and higher organic loads without the need for expanding the physical footprint of the wastewater treatment plant.
How the MBBR Works
An MBBR is one of several types of aerobic biological wastewater treatment process that uses bacteria to consume organic matter in the presence of oxygen. The main difference between the MBBR and other conventional processes is that is uses small plastic carrier elements in the biological aeration vessel to provide a high surface area for biomass to attach to and grow. These carrier elements allow a very high concentration of biomass to be present in the bioreactor which effectively increases its biological treatment capacity and allows greater volumes of wastewater to be treated in considerably smaller vessels.
The Stages of the MBBR Process
- Wastewater is introduced into the aeration tank containing the carrier elements at a constant flow rate where oxygen is introduced.
- Biologically treated wastewater flows out of the aeration tank directly into a HyDAF dissolved air flotation system.
- The HyDAF dissolved air flotation system removes the biomass in the wastewater via flotation and the treated water flows to the point of discharge.
- The removed biomass is either dewatered and further processed or removed from site as waste activated sludge (WAS). Some biomass is returned back to the aeration tank as return activated sludge (RAS).
Nutrient Removal
Nitrogen removal can be incorporated into the MBBR process by the inclusion of an anoxic zone upstream of the aeration tank with a mixed liquor return loop that recirculates water between the aeration and anoxic tanks. Some phosphorous will be taken up in the biological process however if very low concentrations are required, the simple addition of coagulant to the DAF inlet will precipitate phosphorous from the clarified water stream to very low levels if necessary.
Highly Efficient Aeration, Sustainable Carriers and Exceptional Process Knowledge
High Quality MBBR Carriers with a high surface area are critical to the performance
The design of the carrier is critical to the performance of the MBBR process and not all carriers are the same. The carriers used in the Hydroflux MBBR are designed based on many years of experience having a specific engineered shape and openings to increase the surface area. It is this openness and shape that has been instrumental in maximising biofilm mass transfer and preventing clogging which otherwise leads to excessive maintenance. All of our carriers are sustainably manufactured primarily from recycled PE and injection molded to provide a hard and durable biofilm carrier that are resistant to cracking and distortion.
High quality and efficient aeration grids that utilises the entire tank surface area
Process oxygenation and mixing is performed by an advanced aeration system installed in the base of the MBBR aeration basin. The aeration system covers the entire base area allowing the most efficient use of the capacity and surface area. Our aeration system is non-clogging and a practically service free system. The high degree of prefabrication ensures excellent quality and reduces the onsite installation time.
Standard ancillaries
Hydroflux offers proven, expertly designed cages that retain the MBBR media within the aeration tank. These cages are designed with to ensure that the media remains securely contained, avoiding the risk of media clogging or fouling within the system whilst allowing for optimal flow dynamics within the tank and ensuring that the biofilm has maximum exposure to the wastewater for effective treatment.
Foam formation in aeration tanks is a frequent challenge that can result in operational inefficiencies and potential system downtime. To address this, Hydroflux offers automated and semi-automated foam control systems designed to preserve the integrity and efficiency of the MBBR system. Leveraging our extensive expertise in wastewater treatment, we can accurately predict and implement the required components tailored to each specific application.
Why Choose Hydroflux for Your MBBR System Construction?
Unmatched Quality: At Hydroflux, we are committed to delivering high quality MBBR systems with exceptional build quality. We ensure that every system is built to last and operates with maximum efficiency, ensuring long-term performance and reliability. We generally opt for stainless steel panel tanks for aeration but concrete may be more appropriate for larger systems.
Extensive Experience: With years of experience in the wastewater treatment industry, Hydroflux has the technical expertise to design and construct MBBR systems tailored to meet the specific needs of your facility. Our team has successfully completed numerous MBBR installations, providing solutions that exceed client expectations in both performance and cost-effectiveness across many industrial sectors.
Proprietary Equipment for Superior Results: Hydroflux utilises proprietary ancillary equipment such as the HyDAF and Huber Screw Press to enhance the performance of your MBBR system. These advanced systems work synergistically with the MBBR process, ensuring efficient sludge removal, improved solids separation, and reduced operational costs.
Choosing Hydroflux means selecting a trusted partner that combines high-quality systems, specialised equipment, and deep industry expertise to deliver outstanding wastewater treatment solutions.
Contact us for a discussion on biological treatment options for your site.
MBBR FAQs
Yes, MBBR technology is highly effective for treating high-strength wastewater. The system’s moving carrier media provides a large surface area that supports a high concentration of biomass, allowing it to degrade organic pollutants efficiently even in wastewater with elevated pollutant levels. This capability makes MBBR ideal for industries such as food processing, pharmaceuticals, and chemical manufacturing, where wastewater often contains high concentrations of organic materials, oils, or chemicals. The system’s flexibility in handling varying organic loads ensures it can maintain consistent treatment performance despite fluctuations in wastewater strength.
Several variables influence the efficiency of MBBR in treating high-strength wastewater. Key factors include the Organic Loading Rate (OLR), retention time, and oxygen transfer. By adjusting the amount of media, aeration, and hydraulic retention time, the system can be tailored to handle different levels of organic pollutants. Additionally, factors like wastewater temperature and pH can impact microbial activity, requiring careful monitoring and adjustment to maintain optimal performance. With proper management of these variables, MBBR systems can deliver reliable and effective treatment even for the most challenging wastewater streams.
MBBR systems are highly adaptable and can be seamlessly integrated into existing wastewater treatment plants, offering a practical solution for enhancing treatment performance without the need for a complete overhaul. This makes MBBR an ideal choice for facilities that face increasing demand, stricter regulatory requirements, or aging infrastructure. Rather than investing in entirely new treatment facilities, MBBR can be retrofitted into the existing setup, usually by upgrading specific stages such as secondary treatment. For example, it can be introduced to replace or enhance the secondary clarifiers or other biological treatment units, allowing for increased capacity and improved effluent quality while maximising the use of the existing space and equipment.
Additionally, MBBR technology’s flexibility allows it to complement existing treatment processes, such as activated sludge systems, to further optimise performance. It can be used to improve the removal of organic matter, nitrogen, and phosphorus, making it an excellent option for wastewater plants that need to meet stricter discharge regulations. The system’s modular design also means it can be easily scaled up or down based on the plant’s capacity needs. With minimal disruption to operations, MBBR enables facilities to boost treatment capacity, reduce maintenance costs, and meet evolving environmental standards, all while avoiding the need for large capital expenditures.
One of the biggest advantages of Moving Bed Biofilm Reactor (MBBR) technology is its compact footprint and scalability. Unlike conventional activated sludge systems, MBBR does not require large aeration basins or clarifiers, as the biofilm grows on floating plastic carriers that move freely in the reactor. This allows for efficient treatment in a much smaller space. Additionally, expanding capacity is simple—instead of building larger tanks, more carriers can be added to increase treatment efficiency without major modifications.
MBBR also offers operational simplicity and lower maintenance compared to other biological treatment technologies. Since it operates as a continuous-flow system, there is no need for cycle timing or complex process adjustments like in sequencing batch reactors (SBR). Additionally, MBBR systems do not require membrane filtration, eliminating the clogging and frequent cleaning associated with membrane bioreactors (MBR). The lack of sludge recycling also simplifies operation, reducing the need for constant monitoring and adjustments.
Another major benefit of MBBR is its resilience to shock loads. Because the biofilm is attached to the carriers, it remains stable even when there are fluctuations in flow rate or organic load. This makes MBBR highly reliable for treating variable wastewater streams, including those with sudden surges in pollutants.
A Dissolved Air Flotation (DAF) unit is often a better choice than a secondary clarifier for MBBR clarification, especially when dealing with poorly settling sludge. Unlike clarifiers that rely on gravity to settle solids, DAF uses fine air bubbles to float suspended biomass to the surface, making it highly effective for separating detached biofilm and suspended solids. This ensures a more consistent effluent quality, particularly in cases where MBBR sludge is light and does not settle well.
Additionally, DAF produces a thicker sludge (around 3% solids) compared to clarifiers, reducing sludge handling and dewatering costs. It also offers better removal of fine suspended solids and residual organics, making it ideal for industries with stringent discharge limits. While clarifiers may be suitable for systems with well-settling sludge, DAF provides superior performance, operational flexibility, and a smaller footprint, making it the preferred choice for high-efficiency MBBR clarification.
One of the main challenges with Moving Bed Biofilm Reactor (MBBR) systems is biofilm sloughing and uneven growth. Over time, biofilm thickens on the carrier media, and if growth becomes excessive, large chunks can slough off, leading to fluctuations in treatment performance and increased suspended solids in the effluent. Conversely, if biofilm growth is insufficient due to inadequate aeration, low organic loading, or chemical exposure, the system may not achieve optimal biological treatment. Proper aeration, organic loading balance, and occasional seeding of new biomass help maintain stable biofilm development.
Issues such as carrier media loss and clogging or fouling can be problematic in some MBBR systems, but they are not a concern with Hydroflux’s design due to the advanced carrier selection and properly engineered ancillary components. Hydroflux systems incorporate high-efficiency retention sieves and well-sized screens, ensuring that carrier media remain securely within the system. This prevents loss of media and maintains consistent treatment efficiency.
Similarly, carrier clogging and fouling due to fats, oils, grease (FOG), or particulates are minimised in Hydroflux MBBR systems. The carriers are designed for self-cleaning through continuous movement and optimised aeration patterns. Additionally, pre-treatment steps, such as grease traps and dissolved air flotation (DAF) units, are recommended where necessary to prevent excessive loading. These design features ensure that Hydroflux MBBR systems operate at peak efficiency with minimal maintenance concerns.
Why Industry Chooses to Work with Hydroflux
Hydroflux has the expertise and capability to deliver design-and-construct projects using a range of primary treatment systems, biological processes, and tertiary treatment methods to enable reuse. We offer flexible contract options, ranging from equipment design and supply to full turnkey installations.
With a team of qualified civil, mechanical, chemical, and electrical engineers, as well as experienced project managers, site supervisors, commissioning engineers, and service technicians, Hydroflux ensures expert execution at every stage. Our offices across Australia provide a strong local presence, ensuring seamless project management from design through to installation. Additionally, Hydroflux offers post-installation routine service contracts to maintain system performance and longevity.
Sustainable Solutions
As Australia’s first certified carbon-neutral water and wastewater chemical supply and service business, we focus on sustainability. Developing and delivering sustainable solutions for treatment plant operation and maintenance is at the core of what we do. Our equipment is the most sustainable in the Australian and New Zealand markets and is not just effective, but also carbon-neutral. Click here to find out what this means for you.
