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TECHNICAL PRESENTATION ON BIO-TOWERS

BY SAI ENVIRO ENGINEERS PVT. LTD.

BIOLOGICAL TREATMENT SYSTEMS


A Biological Treatment (secondary) which removes the dissolved organic matter from the waste water can be categorized into different systems primarily based on the bacterial growth pattern. Suspended Growth : Bacteria is in suspension in the reactor, free mobility, continuous loss of bacterial culture in the outlet. Ex : Activated Sludge Process (ASP), Extended Aeration, etc. Attached Growth : Bacteria attached to a surface of media, no mobility, no loss of microbes, Media with higher surface area provided for bacterial growth. Ex : SAFF, FAB, Bio-towers, etc.

BIO-TOWER SYSTEM
CONCEPT Bio-tower is a modernized trickling filter which is designed as a roughening tower for BOD / COD reduction from the influent. Bio-tower is used as a first stage aerobic biological treatment where multi stage treatment is required.

Why Bio-tower ? Bio-tower is equipped with PVC structured media which provides larger surface area in the tune of 100m2/m3, hence it occupies less space. No lateral load of media and is self supporting, hence skeletal civil structure suffices. This results in low construction costs. Low power consumption - to the tune of up to 1/4 th of conventional ASP and 1/6 th of Extended Aeration plant. A bio-tower system can reduce upto 60 80% BOD easily when two towers are equipped in series. Where ? A bio-tower can be used where a multi stage biological treatment process is required to break the complex organics. A bio-tower can be used where the system is required to take care of shock loads in terms of both hydraulic and organic disturbances.

WHY and WHERE ?

APPLICATIONS
Municipal Sewage Pharmaceutical Industry Distillery Paper Mill, Paint Food Processing Dairy Sugar Brewery

CONSTRUCTION AND MECHANISM Bio-tower is constructed with Civil Columns and beam supports. Bio-tower is filled with PVC structured bio-fill media. A recirculation pump arrangement shall be made at the sump to feed the effluent to the top of the tower and sprinkle, where the media adhered micro-organisms will degrade the organic matter as BOD. This will help in meeting the necessary wetting rate of bio-fill media. Part of the effluent from recirculation line flows to next unit for further treatment. Bio-tower will not clog as like ordinary stone media filters. Excess biomass on the Bio-tower plastic media automatically removed due to the recirculation flow.

BIO-FILL MEDIA

Synthetic media in a bio tower system results in a greater surface area available for biological growth per cubic mtr. of bio-tower volume. Because of the less weight of synthetic media, bio-towers can be built upto 6 mtrs. This results in the ability to handle greater loads.

INSTALLATION OF A BIO-TOWER SYSTEM

TREATMENT PROCESS IN BIOTOWER


Aerobic bacteria clings to the surface of media and stays in the system in the form of biofilm Organic matter in wastewater comes in contact with the bacteria Bacteria consumes the organic matter and releases CO2, H20, HUMUS

As the layer grows in thickness, bottom layers turns into anaerobic because of lack of O2 Also, organic matter does not reach bottom layers and the bacteria goes into endogenous phase and gets detached from media. This is called SLOUGHING

ADVANTAGES OF BIO-TOWER SYSTEM Attached growth systems can take more shock loads in terms of hydraulic and organic disturbances as compared to suspended growth systems. High purification rates. Trouble free operations even under difficult conditions. Semi skilled operation, very less maintenance requirements and thus low operation and maintenance costs. Void ratio is more than 95% and hence media height can be up to 7-8mtrs. Low sludge production about 0.15-0.2kg/kgBOD reduced (ASP-0.3-0.4kg/kgBOD; EA-0.25-0.3kg/kgBOD)

Lower residual suspended solids concentration in treated wastewater is observed. A bio-tower serves as a cost effective combination with other treatment methods. Less foot print area required compared to conventional system. Improved plastic media design such as the cross flow media have significantly reduced bio-tower size & cost and enhanced their efficiencies. No need for Mechanical or Diffused Aeration. This works on Natural Draft.

a. b. c. d. e. f. g. h.

General Advantages of Structured Media For Bio-tower Long life of over 30 years - UV stabilized material. Large specific surface area - 100 Sq. m / Cu. m Very large voidage >97 %. Low dry weight 30 kg / Cu. m leads to cheaper & simpler supporting structure. The distribution pattern ( 600 cross fluted ) provides utilization of the complete surface area Large heights - say 6 - 8 M - Allow considerable saving of land Due to cross flow configuration, liquid has about 4 times higher detention time. Good wetting, continuous air movement and thinner biological growth lead to ZERO fly nuisance

COMPARATIVE STUDY

DESCRIPTION

CONVENTIONAL Aeration System


1000 m3/day 41.66 m3/hr 250 mg/lit =250 kg/d 334 m3 2.5 m Diameter: 13m 133 m2 700 m3/hr Required to maintain MLSS concentration

Bio-Tower/ Trickling Filter


1000 m3/day 41.66 m3/hr 250 mg/lit =250 kg/d 215 m3 6.0 m 6m x 6m 36 m2 Natural Draft Air is sufficient N.A. Large Microbial growth on media suffices Yes

Flow rate

BOD Inlet

Volume of Tank Tank depth Tank dimensions Area Required Actual Air Requirement Sludge Recirculation

Pumping Requirement

Yes

COST ANALYSIS
DESCRIPTION CONVENTIONAL aeration System
=133+(0.3*133) = 172 Sq.m

Bio-Tower/ Trickling Filter


=36+(0.3*36) = 50.00Sq.m Total Land cost Rs 12,500/Cost of Frame Work= Rs.1,00,000/-

Land Requirement

Land cost Total Land cost Land Cost @ Rs 250 Rs 43,000// Sqm. Civil Work Volume of tank=334 m3 Civil cost @Rs.2000/m3= Rs.6,68,000/N.A.

Bio Tower Media

170 cu.m x 3000 = Rs.5,10,000/-

COST ANALYSIS
DESCRIPTION CONVENTIONAL Aeration System Diffuser cost = 82 Nos. x N.A. 5000 = Rs. 4,10,000/Air Piping= Rs. 1,00,000/N.A. Rs.50,000/Bio-Tower/ Trickling Filter

Diffused Aeration system Water Distribution system Pump Requirement

2 (1W + 1SB) =Rs. 2,00,000/2 (1W + 1SB) =Rs.4,00,000/=18.2 Lacs

2 (1W + 1SB) =Rs. 4,00,000/N.A.

Blower Assembly

TOTAL COST

=10.72 Lacs

PARTIAL LIST OF BIO-TOWER INSTALLATIONS


SR. NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. CLIENT GMR INDUSTRIES LTD., KARNATAKA RUBBER PARK INDIA LTD., KERALA NARMACS DAIRY, ANDHRA RADESH MATRIX LABORATORIES, A.P. SUNIL HITECH ENGINEERS LTD., MH. AVON ORGANICS LTD., A.P. VERA LABORATORIES, A.P. SHARAT INDUSTRIES LTD., A.P. FOOD & INNS LTD., A.P. JASPER AQUA EXPORTS LTD., A.P. TYPE OF INDUSTRY SUGAR RUBBER DAIRY BULK DRUG SUGAR & CO-GEN FINE CHEMICALS PHARMA SEA FOOD FRUIT PULP SEA FOOD CAPACITY 1.0 MLD 250 KLD 600 KLD 200 KLD 4.1 MLD 300 KLD 250 KLD 200 KLD 200 KLD 150 KLD

THANK YOU

SAI ENVIRO ENGINEERS PVT. LTD.