MBBR Technology
Moving Bed Biofilm Reactor - Compact, efficient biological wastewater treatment with superior organic removal performance
Overview
What is MBBR Technology?
Moving Bed Biofilm Reactor (MBBR) technology represents a breakthrough in biological wastewater treatment, combining the benefits of both suspended growth and attached growth systems. This innovative process utilizes specially designed plastic carrier media that provide a large protected surface area (typically 500-800 m²/m³) for biofilm growth while moving freely within the reactor.
The MBBR system operates by maintaining biofilm-covered carriers in continuous motion through aeration or mechanical mixing. This movement ensures optimal contact between wastewater, biomass, and oxygen, resulting in highly efficient organic matter removal (85-95% BOD/COD reduction) and nitrification (up to 90% ammonia removal). With typical hydraulic retention times of 2-4 hours and volumetric loading rates of 3-8 kg BOD/m³/day, MBBR systems achieve superior performance in significantly smaller footprints than conventional activated sludge processes.
Spans Envirotech's MBBR solutions incorporate high-performance carrier media with optimized geometries that maximize biofilm surface area while minimizing clogging. Our systems are engineered for easy retrofitting into existing treatment plants, offering a cost-effective upgrade path to enhance capacity by 50-100% without requiring significant civil construction. Typical energy consumption ranges from 0.8-1.5 kWh/m³ treated, with operational costs 20-30% lower than conventional systems due to reduced sludge production (30-50% less than activated sludge) and minimal maintenance requirements.
Advanced Bio Cavity Media configurations provide protected surface areas of 4,000–5,000 m²/m³ — up to 10 times higher than conventional MBBR media — enabling biodegradation rates up to 10x higher than standard carriers in the same reactor volume. The fine pore structure of Bio Cavity Media retains a thin, highly active biofilm that resists mechanical damage while preventing clogging. MBBR systems can also be operated in IFAS (Integrated Fixed-Film Activated Sludge) mode, adding media to an existing activated sludge tank to increase biological capacity by 50–100% without constructing new tanks.
Process
How MBBR Technology Works
Carrier Media Introduction
Specialized plastic carriers with large surface areas are added to the reactor tank, typically filling 40-70% of the reactor volume. These carriers provide protected surfaces for biofilm attachment.
Biofilm Development
Microorganisms colonize the carrier surfaces, forming a dense biofilm. The protected internal surfaces prevent biofilm from being washed away during high-flow conditions.
Continuous Mixing
Aeration systems or mechanical mixers keep carriers in constant motion, ensuring uniform distribution and optimal contact with wastewater while maintaining aerobic conditions.
Biological Treatment
As wastewater flows through the reactor, organic matter and nutrients are consumed by the biofilm. The moving carriers prevent dead zones and ensure consistent treatment performance.
Effluent Separation
A retention screen at the reactor outlet retains carriers while allowing treated water to flow through to the next treatment stage. Minimal sludge production simplifies downstream handling.
Benefits
Key Advantages
- Compact footprint - up to 50% smaller than conventional activated sludge systems
- High volumetric loading capacity with excellent organic removal efficiency (85-95% BOD/COD reduction)
- Excellent resistance to shock loads and toxic substances due to protected biofilm
- Easy retrofitting into existing tanks to upgrade treatment capacity
- Low operational costs with reduced sludge production compared to activated sludge
- No biofilm sloughing issues - carriers protect biomass from hydraulic shearing
- Simple operation with minimal maintenance requirements
- Bio Cavity Media achieves 4,000–5,000 m²/m³ surface area — up to 10x higher biodegradation rates than conventional media
- IFAS mode enables retrofitting of existing activated sludge plants without new civil works
Applications
Industries & Use Cases
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