ALMA BIO MBBR – Moving Bed Biofilm Reactor for COD, ammonium, and nitrogen removal
Have an MBBR system designed:
Maksim Neubauer
Head of International Project Development
What is an MBBR reactor?
An MBBR reactor (Moving Bed Biofilm Reactor) is a biological wastewater treatment process in which microorganisms grow as a biofilm on freely moving plastic carriers. These so-called carriers move continuously within the reactor and provide a large, protected surface area for the active biomass.
This allows a high concentration of biologically active biomass to be maintained relative to the reactor volume. The MBBR process is suitable both for the biological degradation of organic carbon compounds and for nitrification —and, with appropriate process control, for denitrification.
Biofilm technology is particularly suitable for industrial wastewater with fluctuating influent loads, peak loads, or limited installation space .
An MBBR reactor is a biological wastewater treatment system in which microorganisms grow on freely moving plastic carriers and biologically degrade organic contaminants and nitrogen compounds.
How does the ALMA BIO MBBR work?
In the ALMA BIO MBBR system, industrial wastewater is treated in several biological process steps. The biomass growing on the carriers breaks down organic contaminants and—depending on the design—also performs nitrogen removal.
Supply wastewater
The pretreated industrial wastewater is fed into the MBBR reactor either continuously or based on the load.
Biofilm on the carriers
Microorganisms colonize the plastic substrates and form a stable, biologically active biofilm there.
Mix the carrier
In aerobic reactor stages, aeration simultaneously ensures the supply of oxygen and the continuous agitation of the biofilm.
Reduce CSB and BSB
Biologically available carbon compounds are metabolized by microorganisms, thereby reducing the organic COD and BOD loads.
Nitrifying ammonium
When the system is designed appropriately, nitrifying microorganisms convert ammonium under aerobic conditions to nitrate.
Reduce nitrogen
In upstream or downstream anoxic zones, nitrate can be biologically denitrified, thereby reducing the total nitrogen.
Separate biomass
Excess biomass is discharged and, depending on the plant design, separated from the biologically treated wastewater using a suitable solids separation process.
Advantages of the MBBR Process
The combination of biomass that grows firmly on the carriers and freely moving growth structures enables compact, flexible, and load-resistant biological wastewater treatment.
High biological activity
The carriers provide a large, protected surface area for the biofilm, thereby enabling a high concentration of biologically active biomass in the reactor.
Stable under impact loads
The biomass established on the growth media remains in the system and supports robust operation under fluctuating COD and hydraulic loads.
Compact design
Due to the high biomass density, MBBR systems can be implemented for many applications with comparatively small reactor volumes and space requirements.
CSB and Nitrogen Removal
Depending on the reactor configuration, organic contaminants, ammonium, and total nitrogen can be reduced using different biological stages.
Existing systems can be retrofitted
MBBR stages can be integrated into existing wastewater treatment plants to increase capacity, stabilize the process, or improve biological performance.
Flexible Designs
From compact PE/PP reactors to stainless steel, and on to large-volume concrete tanks or container-based systems, the design can be adapted to the throughput and location.
Case Studies in Aerobic Biological Wastewater Treatment
Sugar Industry, Pemuco, Chile
Nitrification and denitrification with integrated degassing and sedimentation for a wastewater flow rate of 120 m³/h.
Abraham Benelux S.A., Belgium
Compact biological wastewater treatment plant in a container design with a capacity of 35 m³/d.
Paper mill, Southern Germany
Removal of biologically difficult-to-degrade COD via biofiltration at a flow rate of 700 m³/h.
Sugar Industry, Germany
Anaerobic treatment and aerobic post-treatment for 220 m³/h from the sugar industry.
Dairy, process water, Germany
Biofiltration for further COD removal in the water reuse process, designed for 600 m³/d.
Top Harvest Yanchang Coal, China
Biological wastewater treatment for 1,500 m³/h with an upstream DAF stage for the pretreatment of refinery wastewater.
Carrier and Biofilm Surface Area—Critical Factors for MBBR Design
The selection of carriers or growth media is a key component of the process engineering design of an MBBR reactor. Depending on the wastewater load, treatment objective, and biological process, different carrier geometries and specific growth surface areas are used.
With the ALMA BIO MBBR, the carrier geometry is not selected based on a one-size-fits-all standard, but rather according to the actual biological load and the desired treatment objective.
CSB, BSB, and ammonium loads form the basis for the required biological performance.
The geometry and specific surface area are selected to suit the wastewater, biofilm process, and reactor conditions.
What matters is not the maximum nominal area, but the surface area that is biologically usable under real-world conditions.
What factors determine carrier design?
- Organic COD and BOD load
- Ammonium load
- Desired nitrification capacity
- Wastewater Temperature
- Oxygen demand
- Wastewater Composition
- Possible inhibitors
- Available reactor area
- Desired Safety Reserves
A carrier surface area that is as large as possible is not automatically the best solution. The key factor is which surface area is sufficiently aerated under actual process conditions and reliably supplied with oxygen, substrate, and nutrients.
CSB, Ammonium, and Nitrogen Removal Using MBBR
Through the targeted combination of aerobic and anoxic biofilm stages, the ALMA BIO MBBR can be used both to reduce organic loading and for biological nitrogen treatment.
CSB and BSB Degradation
Heterotrophic microorganisms in the biofilm biologically degrade available organic carbon compounds. This reduces COD and BOD and alleviates the load on downstream treatment stages.
Nitrification
Nitrifying microorganisms convert ammonium under aerobic conditions first to nitrite and then to nitrate. The biofilm helps ensure that the slow-growing nitrifying bacteria remain in the reactor.
Denitrification
For further nitrogen removal, anoxic MBBR stages can be incorporated. There, nitrate is biologically reduced to elemental nitrogen.
When is an MBBR reactor particularly suitable?
MBBR systems are particularly well-suited for industrial wastewater applications that require a compact biofilm stage, high process stability, and flexible adaptation to varying load conditions.
An MBBR is particularly useful in situations where a robust biofilm stage with high biomass densityis required, and where the biological treatment must simultaneously remain as stable as possible in the face of hydraulic or organic load peaks.
MBBR or activated sludge—what are the differences?
Both processes use microorganisms for biological wastewater treatment. The main difference lies in how the active biomass is retained in the reactor.
| Criterion | MBBR | Conventional activated sludge process |
|---|---|---|
| biomass | Primarily as a biofilm on carriers | Predominantly freely suspended |
| Biomass retention | Through the carrier in the reactor | About Return Sludge |
| Impact Loads | High process robustness | More dependent on the age of the sludge and recirculation |
| Space requirements | Often compact | Larger tank volumes are often required |
| Extensibility | Carriers or additional biofilm stages are possible | Additional basins are often required |
| Nitrification | Very feasible | Also quite feasible |
| Retrofit | Well-suited for expansion projects | Often, more extensive construction projects |
An MBBR differs from the conventional activated sludge process primarily in that a significant portion of the microorganisms is retained as a biofilm on freely moving plastic carriers within the reactor.
MBBR or MBR—what's the difference?
MBBR and MBR are often confused with each other, but they differ, particularly in terms of biomass retention and solids separation.
MBBR
In a moving-bed biofilm reactor, the biomass grows primarily as a biofilm on moving carriers. Excess biomass is discharged from the reactor and subsequently separated from the treated wastewater via a separate solids separation process. treated wastewater.
MBR
In a membrane bioreactor, biological treatment is combined with membrane filtration. The membrane retains biomass and solids, thereby allowing for a nearly solids-free effluent.
An MBR is particularly suitable when very high treatment quality or more extensive water reuse is required. An MBBR, on the other hand, is particularly appealing when the focus is on a robust, compact, and load-stable primary biological treatment stage.
Automated Process Control of the ALMA BIO MBBR
The biological performance of an MBBR depends largely on oxygen supply, hydraulic load, and organic load. The ALMA BIO MBBR can therefore be equipped with a load-dependent process control system.
Flow Measurement
The current wastewater flow serves as a key basis for hydraulic control and the assessment of the system load.
Oxygen measurement
The oxygen concentration is continuously monitored and can be used to adjust aeration as needed .
Integrated CSB Measurement
Continuous or automated COD measurement enables a better assessment of the actual organic load in the influent.
Automatic Ventilation Control
The air supply can be adjusted based on the current process values to account for the biological load and the oxygen demand.
Process Data & Trend Analysis
Measurement data and operating conditions can be visualized, analyzed, and used to continuously optimize the biological process.
Have an MBBR system designed:
Maksim Neubauer
Head of International Project Development
Technical Design of the ALMA BIO MBBR
The ALMA BIO MBBR is customized for each project to meet specific requirements for hydraulic capacity, biological load, treatment objectives, and existing infrastructure. The reactor design, carriers, aeration, and automation systems are all designed in conjunction with one another.
| Parameters | Design |
|---|---|
| Procedure | Moving-Bed Biofilm Reactor |
| Hydraulic power | 20–5,000 m³/h |
| Carrier growth area | approx. 50–750 m²/m³ |
| Carrier Selection | Tailored to each project based on wastewater load and treatment objectives |
| Reactor Design | Concrete, stainless steel, PE/PP, or containers |
| Biological Objectives | CSB/BSB Removal, Ammonium Removal, and Nitrogen Elimination |
| Ventilation | Project-Specific Ventilation Systems |
| Measurement | Flow, oxygen, and integrated COD measurement |
| Automation | Load-Dependent Process Control |
| System Integration | New and Existing Facilities |
Typical industrial applications
The ALMA BIO MBBR is suitable for various types of industrial wastewater containing biodegradable organic pollutants, as well as for applications requiring nitrification and nitrogen removal.
Food industry
Treatment of organically loaded industrial wastewater with fluctuating COD and BOD loads.
Beverage Industry & Breweries
Biological degradation of readily available organic pollutants as well as advanced nitrogen treatment.
Dairies
Treatment of industrial wastewater with high organic loads and significant fluctuations in production.
Chemical industry
Biological treatment of suitable biodegradable fractionates following appropriate pretreatment.
Pharmaceutical & cosmetics industry
Biofilm stages for reducing biodegradable organic loads and nitrogen compounds.
Recycling & Waste Disposal
Biological post-treatment of industrial wastewater that has undergone chemical-physical pretreatment.
What data do we need for the MBBR design?
To develop a robust initial design, we need information on the hydraulic load, organic load, and nitrogen load, as well as on the desired effluent parameters and the existing site conditions.
Key Data for the Initial Design
- Average and Maximum Flow Rate
- CSB and BSB
- Dissolved and Total CSB
- Ammonium nitrogen
- Total nitrogen
- Phosphorus
- pH value
- Wastewater Temperature
- Solids content
- Hours of Operation
- Daily and Weekly Profiles
- Peak loads
- Existing Pretreatment
- Desired flow rates
- Existing pool or available installation space
- Known inhibitors or contaminants
Based on your wastewater analysis and the desired effluent parameters, we determine the reactor volume, carrier type, required carrier quantity, oxygen demand, and the appropriate system configuration.
Photos of aerobic wastewater treatment plants
FAQ - ALMA BIO MBBR Suspended-Bed Reactor
What does MBBR stand for?
MBBR stands for Moving Bed Biofilm Reactor. In this process, microorganisms grow as a biofilm on freely moving plastic carriers inside the reactor. The carriers provide a large, protected surface area for the biomass, thereby enabling compact biological wastewater treatment.
What are the advantages of an MBBR system when wastewater loads fluctuate?
The biomass growing on the carriers remains in the reactor permanently and is not flushed out of the system with every hydraulic fluctuation. As a result, an MBBR can respond with relative robustness to fluctuations in COD, BOD, or ammonium loads, as well as to typical production peaks.
Can an MBBR be used for the nitrification of ammonium?
Yes. With proper design, nitrifying microorganisms can colonize the carriers and oxidize ammonium to nitrate under aerobic conditions. The required reactor and carrier design depends in particular on the ammonium load, temperature, oxygen supply, and the required effluent quality.
Can an existing biological wastewater treatment plant be retrofitted with MBBR?
Yes. MBBR technology is particularly well-suited for expanding the capacity and improving the performance of existing biological wastewater treatment plants. Depending on the existing tank geometry, carriers, retention systems, and aeration can be added, or additional MBBR reactors can be installed.
Does an MBBR require sludge recirculation?
In a conventional MBBR system, the biofilm growing on the carriers does not require a return sludge stream, as is the case with the conventional activated sludge process. However, biomass that has been released from the biofilm and newly formed biomass must be removed from the treated wastewater using a suitable solids separation process.
How long does it take to commission an MBBR reactor?
Biological start-up is project-specific and depends, among other factors, on the composition of the wastewater, temperature, available inoculum, and the intended load. The organic load is typically increased gradually as the active biofilm develops and stabilizes on the carriers.
For which types of industrial wastewater is an MBBR suitable?
MBBR systems are particularly well-suited for biodegradable industrial wastewater from, for example, food, beverage, dairy, chemical, pharmaceutical, cosmetics, or recycling processes. Before designing the system, an assessment is conducted to determine whether the wastewater is sufficiently biodegradable and whether inhibitory or toxic substances require pretreatment.
Our Reactors for Aerobic Wastewater Treatment
ALMA BHU BIO
The ALMA BHU BIO System combines nitrification, denitrification, and sedimentation with biomass recirculation to increase conversion rates.
ALMA BIO BBI
The ALMA BIO BBI system is characterized by its integrated sedimenter, which makes it extremely space-saving compared to similar systems.
ALMA BAF
Biologically activated filtration (BAF) uses sessile microorganisms to remove organic compounds (BOD, COD) and nitrogen from wastewater.
ALMA BIO MBBR
Biological wastewater treatment using free-floating biofilters for the efficient reduction of carbon and nitrogen compounds.
ALMA BIO SBR
A sequentially operated bioreactor with distinct phases for biological treatment, sedimentation, and clear water discharge.
ALMA BHU BIO DEA
Biological deammonification process for energy-efficient nitrogen removal from wastewater with high ammonium content and low oxygen demand.
ALMA BIO Compact MBBR
Containerized MBBR system for biological wastewater treatment, offering high treatment capacity per unit area and rapid integration into operations.
ALMA BioFil Compact
Our compact biologically activated filtration in tank design, equipped with special growth bodies for effective biomass growth.
ALMA BIO MBR
Membrane bioreactor with submerged plate modules or an externally mounted ultrafiltration unit in a robust tubular module design.
Have an MBBR system designed:
Maksim Neubauer
Head of International Project Development