UASB/EGSB anaerobic reactors combined with MBBR aerobic polishing for very high COD/BOD (>3,000 mg/L) wastewater with biogas energy recovery potential.
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Upflow anaerobic sludge blanket or expanded granular sludge bed reactors for high-rate COD conversion to biogas (CH₄ + CO₂).
Biogas collection, H₂S scrubbing, and utilisation for boiler fuel, CHP generation, or process heating. Safety monitoring included.
Post-anaerobic aerobic MBBR for residual COD removal, nitrification, and polishing before discharge or reuse.
Iron, nickel, cobalt dosing for anaerobic microbial health with automated feedback control based on reactor performance.
| Parameter | 10–25 m³/h | 25–50 m³/h | 50–100 m³/h | 100–200 m³/h |
|---|---|---|---|---|
| Anaerobic Reactor | UASB compact, 10 m³ | UASB, 20 m³ | UASB (2×), 20 m³ each | UASB (2×), 30 m³ each |
| OLR (Organic Loading) | 5–10 kg COD/m³/day | 5–10 kg COD/m³/day | 8–15 kg COD/m³/day | 8–15 kg COD/m³/day |
| HRT | 24–48 hours | 24–48 hours | 18–36 hours | 18–36 hours |
| COD Removal (Anaerobic) | 70–85% | 70–85% | 75–90% | 75–90% |
| Biogas Production | 0.3–0.5 m³/kg COD | 0.3–0.5 m³/kg COD | 0.35–0.5 m³/kg COD | 0.35–0.5 m³/kg COD |
| CH₄ Content | 60–70% | 60–70% | 60–70% | 60–70% |
| Aerobic Polishing | MBBR post-tank | MBBR 2-stage | MBBR 2-stage + clarifier | MBBR 2-stage + disc filter |
| Total COD Removal | >95% | >95% | >97% | >97% |
| Power | 20–35 kW (net, with CHP) | 35–60 kW | 60–100 kW | 100–180 kW |
| SCADA | Tier 2–3: Advanced | Tier 3: Advanced | Tier 3–4: Enterprise | Tier 4: DCS |
Stillage and spent wash with very high COD (>50,000 mg/L).
Blood, fat, and protein-rich wastewater from slaughterhouses.
Sugar-rich wastewater with high soluble COD.
Black liquor and process water with high lignin content.
Fermentation broth and cell culture waste with high organic loading.
Sites wanting to recover energy from high-strength wastewater.
Complete equipment inventory for Option F — Anaerobic + MBBR. Process train: Yes | SCADA: Tier 3–4
Biogas ATEX, gas detection, flame arrestors
| Item Code | Description | Qty | Spec / Notes | Location |
|---|---|---|---|---|
| F-ME-01 | Inlet screen | 1 | 3–6 mm manual or automatic | Inlet |
| F-ME-02 | Anaerobic reactor (UASB/EGSB) | 1 | SS316L or coated CS, 8–16 m height, internal GLS | Anaerobic |
| F-ME-03 | Three-phase separator (UASB) | 1 set | SS316L, gas-tight, internal | Anaerobic |
| F-ME-04 | Biogas collection header | 1 | SS316L, water seal + flame arrestor | Anaerobic |
| F-ME-05 | MBBR media (biofilm carriers) | 1 fill | HDPE, density 0.96, 500 m²/m³ | Aerobic |
| F-ME-06 | MBBR aeration grid / diffusers | 1 set | EPDM fine bubble, 8–12 m depth | Aerobic |
| F-ME-07 | Secondary clarifier / DAF | 1 | Lamella or DAF, SS316L | Clarifier |
| F-ME-08 | Sludge scraper | 1 | Central drive, SS316L | Clarifier |
| F-ME-09 | Sludge thickener (optional) | 1 | Gravity drum or belt | Sludge |
| F-ME-10 | Dewatering unit (optional) | 1 | Screw press or centrifuge, 15–22% DS | Sludge |
| Item Code | Description | Qty | Spec | Driver |
|---|---|---|---|---|
| F-PU-01 | Inlet lift pump | 2 | 1 duty + 1 standby, submersible or dry-mount | VFD |
| F-PU-02 | Anaerobic recirculation pump | 2 | 1 duty + 1 standby, centrifugal | Fixed/VFD |
| F-PU-03 | Effluent transfer pump (MBBR to clarifier) | 2 | 1 duty + 1 standby, centrifugal | Fixed/VFD |
| F-PU-04 | Sludge recirculation / waste pump | 2 | 1 duty + 1 standby, progressive cavity | Fixed |
| F-PU-05 | Clarifier sludge pump | 1 | Progressive cavity, 1–5 m³/h | Fixed |
| F-PU-06 | Dewatering feed pump | 1 | Progressive cavity, variable speed | VFD |
| F-PU-07 | Polymer dosing pump (dewatering) | 1 | Diaphragm or progressive cavity, 5–50 L/h | Fixed |
| F-PU-08 | Effluent discharge pump | 2 | 1 duty + 1 standby | Fixed/VFD |
| Item Code | Description | Qty | Range / Output | Tier |
|---|---|---|---|---|
| F-SI-01 | Inlet flow meter | 1 | Magnetic or ultrasonic | All |
| F-SI-02 | Outlet flow meter | 1 | Magnetic | All |
| F-SI-03 | pH (inlet / EQ) | 1 | 0–14 pH | All |
| F-SI-04 | pH (anaerobic effluent) | 1 | 0–14 pH | Tier 2+ |
| F-SI-05 | pH (MBBR outlet) | 1 | 0–14 pH | Tier 2+ |
| F-SI-06 | Temperature (anaerobic reactor) | 1 | PT100, 0–80°C | Tier 2+ |
| F-SI-07 | Biogas flow meter | 1 | Thermal mass or vortex, 0–500 m³/h | Tier 3 |
| F-SI-08 | Biogas H₂S analyser | 1 | 0–5,000 ppm, electrochemical or UV | Tier 3 |
| F-SI-09 | Biogas CH2 / CO₂ analyser | 1 | Infrared, 0–100% | Tier 3 |
| F-SI-10 | Dissolved oxygen (MBBR) | 1 | 0–10 mg/L, optical | Tier 2+ |
| F-SI-11 | MLSS / TSS (MBBR) | 1 | 0–20 g/L, optical or ultrasonic | Tier 3 |
| F-SI-12 | Turbidity (outlet) | 1 | 0–100 NTU | Tier 2+ |
| F-SI-13 | COD / TOC online (optional) | 1 | UV254 or colorimetric | Tier 3 |
| F-SI-14 | Level (all tanks) | 4–6 | Ultrasonic / hydrostatic | All |
| F-SI-15 | Gas detection (H₂S, CH2, CO) | 2–3 | ATEX-rated, alarm + trip | Tier 3 |
| Item Code | Description | Qty | Spec | Notes |
|---|---|---|---|---|
| F-DS-01 | Acid dosing pump | 1 | Diaphragm | pH |
| F-DS-02 | Caustic dosing pump | 1 | Diaphragm | pH / alkalinity |
| F-DS-03 | Nutrient (N) pump | 1 | Diaphragm | MBBR |
| F-DS-04 | Nutrient (P) pump | 1 | Diaphragm | MBBR |
| F-DS-05 | Trace metal (Fe, Ni, Co) | 1 | Diaphragm, 0–10 L/h | Anaerobic |
| F-DS-06 | Alkalinity (soda ash) | 1 | Diaphragm | Nitrification |
| F-DS-07 | Polymer (clarifier) | 1 | Progressive cavity | Settling |
| F-DS-08 | Chlorine / hypochlorite | 1 | Diaphragm | Disinfection |
| F-DS-09 | Day tanks | 5–7 | 200–500 L, PE, bunded | Dosing skid |
| Item Code | Description | Qty | Spec | Tier |
|---|---|---|---|---|
| F-SC-01 | PLC | 1 | S7-1500 or ControlLogix | Tier 3–4 |
| F-SC-02 | HMI | 1 | 15", IP65 | Tier 3–4 |
| F-SC-03 | Biogas safety PLC | 1 | Safety-rated, separate from process | Tier 3 |
| F-SC-04 | DO control + blower VFD | 1 | PID cascade | Tier 3 |
| F-SC-05 | VFD panel (all pumps + blowers) | 1 | 6–10– VFDs, 1.5–22 kW | Tier 3 |
| F-SC-06 | Remote I/O | 3–4 | Distributed | Tier 3 |
| F-SC-07 | 4G/WiFi router | 1 | Industrial, VPN | Tier 3 |
| F-SC-08 | Gas detection alarm panel | 1 | Separate from process PLC | Tier 3 |
| F-SC-09 | UPS | 1 | 2–3 kVA | Tier 3 |
| F-SC-10 | MCC / control room | 1 | SS304, IP55, air-conditioned, positive pressure | Tier 3–4 |
| Item Code | Description | Qty | Spec |
|---|---|---|---|
| F-AU-01 | Anaerobic process blower (mixing, if EGSB) | 1 | Small rotary lobe, 0.5–1.5 kW |
| F-AU-02 | MBBR aeration blower | 2 | 1 duty + 1 standby, 2.2–11 kW |
| F-AU-03 | Blower acoustic enclosures | 2 | Noise <75 dB |
| F-AU-04 | Biogas pipework + flame arrestor + PRV | 1 set | SS316L, ATEX rated |
| F-AU-05 | Ventilation fan (explosion-proof) | 3–4 | 200–500 m³/h, ATEX Zone 2 |
| F-AU-06 | LED lighting (explosion-proof in biogas zone) | 4–6 | 20W, IP65, ATEX |
| F-AU-07 | HVAC (positive pressure control room) | 1 | 3–6 kW, over-pressure to prevent gas ingress |
| F-AU-08 | Spill bund | 1 | 110% largest tank |
| F-AU-09 | Pipework & valves | 1 set | SS316L, DN25–DN200 |
| F-AU-10 | Access platforms / grating | 1 set | FRP, anti-slip |
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