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Contents

Preface viiAbout the Editors xiContributors xiii

1. Introduction 1

2. Fundamentals 55

3. Design, Operation and Maintenance 209

4. Commercial Technologies 289

5. Case Studies 359

AppendicesAppendix A Conversion Factors 455Appendix B MBR Biotreatment Base Parameter Values 457Appendix C Membrane Products 463Abbreviations 485Nomenclature 489Glossary of Terms 493Index 497

v

Preface

This is only the second edition of The MBR Book, the first edition having beenpublished in 2006, but it’s the fourth on membrane technology from the Centrefor Water Science at Cranfield University in the United Kingdom. The first ofthese was the original book on membrane bioreactors: Membrane Bioreactorsfor Wastewater Treatment by Tom Stephenson, Simon Judd, Bruce Jeffersonand Keith Brindle, which came out in 2000 (IWA Publishing). This was fol-lowed in 2003 by Membranes for Industrial Wastewater Recycling and Reuse,by Simon Judd and Bruce Jefferson (Elsevier). Since then there have been a fewbooks dedicated to membrane technology for wastewater treatment, three ofwhich were all published in 2006: Membrane Systems for Wastewater Treat-ment (WEFPress, 2006), Membrane Technology for Waste Water Treatment(Johannes Pinnekamp and Harald Friedrich, FiW-Verlag, 2006) and The MBRBook (Elsevier, 2006). As a poignant demonstration of history repeating itself,the publication year of the second edition is the same as that of two otherwastewater membrane reference texts:MBR Practice Report: Operating LargeScale Membrane Bioreactors for Municipal Wastewater Treatment, by Chris-toph Brepols (IWA Publishing) and The Guidebook to Membrane Technologyfor Wastewater Reclamation, led by Mark Wilf (Balaban Publishers).Membrane wastewater books are, it seems, like London buses.

There have also been many more books, both on biological treatmentand membrane technology, which have included sections on MBRs. Acomprehensive listing of these would be challenging. Two of the mostrecent, both from 2008, are Biological Wastewater Treatment, Principles,Modelling and Design, by Mogens Henze, Mark van Loosdrecht, GeorgeEkama and Damir Brdjanovic from IWA Publishing, and AdvancedMembrane Technology and Applications, by Norman Li, Tony Fane, Win-ston Ho and Takeshi Matsuura from Wiley (2008). However, there areseveral books which similarly aim to cover either membrane technology orbiological treatment in a rather more comprehensive manner than providedin The MBR Book. Biological treatment texts include the biotreatment‘bible’ of Metcalf and Eddy: Wastewater Engineering e Treatment andReuse by George Tchobanoglous, Franklin Burton and David Stensel(McGraw Hill, 2003) and also the commendable Biological WastewaterTreatment by Leslie Grady, Glen Daigger and Nancy Love, the third editionof which is also due out in 2010 (IWA Publishing).

Writing the second edition of The MBR Book was initially viewed asbeing a simple enough task, with the format used for the first edition being

vii

serviceable enough, only requiring updates from the past four to five years.However, there has been an explosion of activity over this period; assur-ances to the publisher that this edition would not exceed 30% of the firsthave proven woefully under-conservative. In the intervening period thenumber of discernible MBR membrane products has more than doubled thatof the first edition, and it is acknowledged that the 44-or-so membraneproducts identified and described cannot be considered comprehensive. Thepast five years have also seen some important landmark plants installed eup to 110 megalitres/day in capacity. Scientific studies of MBRs havecontinued to be published at much the same rate as ever e about 20%exponential growth each year since the mid-1990s. It is these developmentsthat have contributed to a 45% expansion of the original text to produce thesecond edition.

As with first edition, the second edition of The MBR Book is set out in sucha way as to segregate the science from the engineering, in an attempt to avoidconfusing, irritating or offending anyone of either persuasion. The book ismeant to include as much practical information as possible, whilst stillcovering the science and technology. There are five chapters, with themembrane and biological fundamentals covered in Chapter 2 along with mostof the scientific studies. The commercial MBR membrane products aresummarized in Chapter 4 and their application to wastewater treatment isdescribed in Chapter 5; the information from Chapter 5 is compiled and usedfor the design section in Chapter 3. New to the second edition are, in Chapter1, summaries of the status of the technology across 13 countries and a briefprecis of research trends. Also, Chapter 3 has been completely redrafted toprovide a cost modelling and cost benefit analysis method, as well as a sectionon operation and maintenance. The latter is considerably more extensive thanin the first edition, and has been informed by an expert panel of practitioners.Extensive cross-referencing between sections and chapters, including figuresor tables in other chapters, is employed to try to ensure a degree of coherencethroughout the tome.

A list of symbols and a glossary of terms and abbreviations are includedat the end of the book, and those relating specifically to the membranetechnology are outlined in Appendix C as a preface to the commercial MBRmembrane module specifications. However, since a few terms and abbrevi-ations are more extensively used than others, and possibly not universallyrecognized, it is probably prudent to list these to avoid confounding somereaders (see following table). It is acknowledged that resolution of theinconsistencies in the use of terms to describe the membrane component ofMBR technologies has not been possible, specifically the use of the terms‘module’ (see Appendix C) and ‘fouling’. This is something which is to beaddressed by the Water Environment Federation (and the best of luck withthat one).

viii Preface

Term MeaningCommon unitsMLD Megalitres/day (thousands of cubic metres per day)LMH L/(m2 h) (litres per square metre per hour)Billion 1000 Million

Process configurationsiMBR Immersed (internal) MBRsMBR Sidestream (external) MBRa-lsMBR Air-lift sidestream MBRanMBR Anaerobic MBR

Membrane configurationsFS Flat sheet (plate-and-frame, planar)HF Hollow fibreMT Multitube

FoulingReversible Removed by physical cleaning, such as backflushing or relaxationIrreversible Not removed by physical cleaning but removed by chemical cleaningIrrecoverable Cannot be removed

AerationSAD Specific aeration demand, either with respect to the membrane area (SADm)

or permeate flow (SADp)

Given the broad range of stakeholders encompassed, it is inevitable thatinconsistencies in terminology, symbols and abbreviations have arisen. It is alsocertain that, despite the best efforts, the text includes a number of inaccuraciesand omissions, for which the authors cannot be held liable. We have, naturally,done everything we could to ensure that the information presented is asaccurate and complete as possible, but, notwithstanding this and because of thecomplex nature of the subject, interested parties are strongly advised to checkfacts and figures with the relevant organisations before acting on any infor-mation provided.

It would be remiss to preface this book without offering the most gratefuland sincere thanks to the many contributors e more than 150 in total. Theseinclude product suppliers, technology providers, consultants, contractors, endusers and academics. Almost all the practical operational data provided havebeen supplied by the technology providers, although corroboration of someinformation from end users has been possible in some cases. All informationproviders are listed in the following section and on the title page of eachchapter, and their assistance, kindness and, at times, superhuman patience inresponding to a plethora of detailed queries by the authors are gratefullyacknowledged. Contributions have also come from academic staff andstudents e predominantly from Cranfield University in the United Kingdom.With regard to the latter, specifically most grateful thanks is offered to currentstudents of, and recent graduates from, the Centre for Water Science and, in

ixPreface

particular (in alphabetical order), Harriet Fletcher, Wenjing Ma, IgnacioMartin, Ewan McAdam, Ana Santos and Bart Verrecht. Gratitude is similarlyexpressed to the incomparable Pierre Le-Clech from the University of NewSouth Wales, who took on the unenviable task of updating the sections onmembrane fouling behaviour in Chapter 2, and to the various members of theDepartment of Applied Mathematics, Biometrics and Process Control at GhentUniversity, who contributed to the modelling sections in Chapter 3.

Special thanks are also given to the Expert Panel members: ChristophBrepols (Erftverband), Dave Hemmings (Aquabio Ltd), Stephen Kennedy(Ovivo), Wilfred Langhorst (Waterschap Hollandse Delta), Dennis Livingston(Ovivo), Heribert Moeslang (Aquantis GmbH), Sameer Sharma (TectonEngineering LLC) and Vincent Urbain (Vinci Environnement), whoseenlightening comments make up the bulk of the operation and maintenancesection of Chapter 3. We are also extremely grateful to Enrico Vonghia at GE,whose encyclopaedic knowledge of even the most obscure MBR membraneproduct market is truly something to behold.

Finally, we would encourage readers to participate in one (or more) of thenow several on-line forums dedicated to the discussion of membrane bioreactortechnology, especially ours (The MBR Group e Membrane Bioreactors atwww.linkedin.com).

As with any piece of work, the editors would welcome any comments fromreaders, critical or otherwise, and our contact details are included in thefollowing section.

SJ and CJ

x Preface

About the Editors

SIMON JUDD

Simon Judd is Professor in Membrane Technology at the Centre for WaterScience at Cranfield University, United Kingdom, where he has been on theacademic staff since August 1992. Since abandoning a chequered career inhairdressing, Simon has co-managed most of the biomass separation MBRprogrammes conducted within the School, comprising 15 individual researchproject programmes and encompassing 13 doctorate students dating back tothe mid-1990s. He has been principal or co-investigator on three major UKResearch Council-sponsored programmes dedicated to MBRs with respect toin-building water recycling, sewage treatment and contaminated groundwaters/landfill leachate, and is also Chairman of the Project Steering Committee onthe multi-centred EU-sponsored EUROMBRA project. As well as publishingextensively in the research literature, Simon has co-authored three textbooks inmembrane and MBR technology, and delivered a number of keynote presen-tations at international membrane conferences on these topics. He is themanager of The MBR Group, an online discussion forum on LinkedIn (www.linkedin.com).

[email protected]/sas/aboutus/staff/judds.html

CLAIRE JUDD

Claire Judd has a degree in German and Psychology and worked as a technicaltranslation editor for three years before moving into publishing. She wasmanaging editor of a national sports magazine, and then co-produced a quar-terly periodical for a national charity before gaining her Institute of Personneland Development qualification in 1995 and subsequently becoming an HRconsultant. She is currently working as a self-employed editor.

xi

Contributors

A number of individuals and organizations have contributed to this book,in particular to the product descriptions in Chapter 4 and the case studiesreferenced in Chapter 5. The editors would like to thank all contributors fortheir co-operation, sometimes at short notice, and acknowledge the particularcontribution of the following (listed in alphabetical order, by organization andlast name; websites, where listed, were accessed in July 2010):

Organization Website Contributor(s)

a2a S.p.A. www.a2a.eu Tullio MontagnoliA3 Water SolutionsGmbH

www.a3-gmbh.com Steffen Richter

ADI Systems Inc. www.adisystemsinc.com Scott Christian, Shannon GrantAlfa Laval BusinessCenter Membrane

www.alfalaval.com Nicolas Heinen

Alfa Laval EnvironmentTechnology

www.alfalaval.com Jessica Bengtsson, Ivar Madsen

Aquabio Ltd www.aquabio.co.uk Geraint Catley, Steve Goodwin,Dave Hemmings

Aquantis GmbH www.vws-aquantis.com Heribert MoeslangArenas de Iguna e Nathalia Perez HoyosAsahi Kasei ChemicalsCorporation

www.asahi-kasei.co.jp Tomotaka Hashimoto,Takehiko Otoyo

Basic American Foods e John S. KirkpatrickBeijing Origin Water www.originwater-int.com Chunsheng Chen, Yili Chen,

Jing Guan, Hui Liang, JianpingWen, Kaichang Yu

BERGHOF MembraneTechnology GmbH &Co. KG

www.berghof.com Eric Wildeboer

Brightwater FLI www.brightwaterfli.com Alan CantwellBUSSE IS GmbH www.busse-is.de Anja BusseCH2M HILL www.ch2m.com Scott Blair, Glen DaiggerCinzac Sales & Service(P) Ltd

www.cinzacsales.com Sebastian Zacharias

City of Peoria, ButlerDrive WRF

e Roger Carr, Raymond F. Trahan

Colloide EngineeringSystems

www.colloide.com Paddy McGuinness

Cranfield University www.cranfield.ac.uk Bruce Jefferson, Paul Jeffrey,Ewan McAdam, Nacho MartinGarcia, Ana Santos, TomStephenson, Bart Verrecht

Dairy Crest e Brian Eddy

xiii


DLT&V SystemsEngineering

www.dltvse.com Uri Papuktchiev

Durban University ofTechnology

www.dut.ac.za Visvanathan Lingamurti(Lingam) Pillay

Dynatec Systems, Inc. www.dynatecsystems.com Gary Lucas, Archie RossEAWAG www.eawag.ch Adriano JossEcologix www.ecologix.com David LoErftverband www.erftverband.de Christoph BrepolsETC Engineering www.etc-eng.it Giuseppe GuglielmiGE Power & Water www.gewater.com Moreno Di PofiGE Water & ProcessTechnologies

www.gewater.com Jason Diamond, BorisGinzburg, Jennifer Pawloski,Jeff Peeters, Enrico Vonghia

GHD Pty Ltd www.ghd.com/australia David de HaasGrundfos BioBooster A/S www.grundfos-biobooster.com Soren Nøhr Bak, Jakob Soholm,

Daniella Weisbort-FeferHainan Litree PurifyingTech. Co., Ltd

www.litree.com Xinzheng Bai, Qing Chen

Hangzhou H-FiltrationMembrane

www.hzfilter.com.cn Hu Juxiang

HERA-AMASA, S.A.Grupo HERA

www.heraholding.com Nacho Manzano, DanielSanchez

Hitachi PlantTechnologies, Ltd

www.hitachi-pt.com Daiju Nakamura

Huber SE www.huber.de Torsten HacknerIllovo Sugar Ltd www.illovo.co.za Bryan Robsoninge GmbH www.inge.ag Martin HeijnenJapan Sewage WorksAgency

www.jswa.jp/en/jswa-en/ Hiroki Itokawa

Kaetsu WwTP e Yukio AzumaKen’s Foods Inc. e Dale MillsKeppel Seghers www.keppelseghers.com Chris DotrementKerafol GmbH www.kerafol.com Christian Muench, Rilana

WeisselKMS Co., Ltd www.koreamembrane.co.kr/eng/

kr_about01.htmJinho Kim, Young-Joo Park

Kobelco Eco-SolutionsCo., Ltd

www.kobelco-eco.co.jp Akira Ishiyama

Koch MembraneSystems

www.kochmembrane.com Olaf Kiepke, ChristophKullmann, Darren Lawrence,Christoph Marner, DirkSchlemper

Kubota Corporation www.kubota.co.jp/english/ Yuusuke OiKubota MembraneEurope Ltd

www.kubota-mbr.com Victor Ferre, Mito Kanai,Xenofon Varidakis

Ladurner Acque www.ladurneracque.it Josef DusiniLam EnvironmentalServices Ltd

www.lamenviro.com Raymond Dai

LG Electronics www.ekored.com Jung-Min (Leonardo) LimMBR Technology� www.aquatorsouthafrica.com Tim Young

xiv Contributors


Membrane ConsultancyAssociates Ltd

www.membraneconsultancy.com

Graeme Pearce

MEMOS MembranesModules Systems GmbH

www.memos-filtration.de Berthold Gunder

Memstar Technology Ltd www.memstar.com.sg Hailin Ge, Jianchun Hong,Jianping Jiang

Metito www.metito.com Bassem TawfikMICRODYN-NADIRGmbH

www.microdyn-nadir.de Stefan Krause, Michael Lyko

Micronet PorousFibers, S.L.

www.porousfibers.com Guillermo Crovetto Arcelus

Mitsubishi RayonEngineering Co., Ltd

www.mrc.co.jp/mre/english/ Shuichi Fujimoto, MinoruOkada

Municipality of Brescia e

MWH Americas Inc. www.mwhglobal.com/MWH/Regions.html

Zakir Hirani

Norit X-Flow BV www.x-flow.com Ronald van’t OeverNOVO Envirotech(Tianjin) Co. Ltd

www.unitedenvirotech.com Li Li

Oerlemans Foods B.V. e Gerard BusserOrelis Environment SAS www.orelis.com Herve PradelleOvivo www.ovivowater.com Steve Kennedy

Dennis LivingstonPolymem www.polymem.fr Olivier LorainPUB www.pub.gov.sg Tao Guihe, Kiran Kekre, Maung

Htun Oo, Jian-Jun Qin andHarry Seah

SABADELL RIU SEC e Jose Ignacio Manzano AndresShanghai Dehong www.dehongkeji.cn Ziying YuShanghai MegaVisionMembrane Engineering& Technology Co., Ltd

www.china-membrane.com Dou Chen, Liu Shoushan, TaoWeixue, Tian Xiaodong

Shanghai Sinap www.sh-sinap.com Liu Dong, Wayne XuShenyang ResearchInstitute of ChemicalIndustry

syrici.lookchem.com Wenjing Ma

Simon Storage e Keith JacksonSumitomo Electric FinePolymer Inc.

www.sei-sfp.co.jp Kiyoshi Ida, Tooru Morita

Superstring MBRTechnology Corp.

www.superstring-MBR.com Yiming Zeng

Suzhou Vina Filter Co.,Ltd

www.vinamem.com Bruce Shing

Tecton Engineering LLC www.tectonme.com Sameer SharmaThames Water www.thameswater.co.uk Eve GermainTianjin MotimoMembrane TechnologyLtd

www.motimo.com.cn Haiping Dai, Weichao Hu

Toray Industries, Inc. www.toray.com Akitoshi Hosoda, NobuyukiMatsuka, Toshitsugu Onoe

xvContributors


Triqua B.V. www.triqua.eu Jan Brinkman, Ingrid WerdlerTrussell TechnologiesInc.

www.trusselltech.com Shane Trussell

Tsinghua University www.tsinghua.edu.cn Xia Huang, Yuexiao Shen, KangXiao

Ultra-Flo Pte Ltd www.ultra-flo.com.sg Jonathan Cray, Joseph Foo, HanHee Juan, Wee Boon Tat

University of Ghent www.ugent.be Thomas Maere, Ingmar NopensUniversiti KebangsaanMalaysia

pkukmweb.ukm.my A. Wahab Mohammad

University of New SouthWales

www.unsw.edu.au Pierre Le-Clech

Veolia Environment www.veolia.com Jean-Christophe SchrotterVeolia EnvironmentalServices

www.veolia-environmentalservices.com

Joy Zhang

Veolia Water www.veoliawater.com Norbert LeBlancVeolia Water Solutions& Technologies

www.veoliawaterst.com Olaf Hanssen

Vinci Environnement www.vinci-environnement.com Vincent UrbainVito www.vito.be Wim DoyenWaterschap HollandseDelta

www.wshd.nl Merle de Kreuk, WilfredLanghorst, Andre Westerdijk

WEHRLE UmweltGmbH

www.wehrle-umwelt.com Matthias Berg, Tony Robinson,Gregor Streif

Weise Water SystemsGmbH

www.weise-water-systems.com Ulrich Weise

Wessex Water www.wessexwater.co.uk Silas WarrenWwTP Hutthurm e Josef KrennWwTP Hans Kupfer e Tom GramerWwTP Monheim e Wolfgang Wild

xvi Contributors

Chapter 1

Introduction

With acknowledgements to (in alphabetical order by organization andcontributor last name):

Section Name Organisation1.2.1 Yiming Zeng Superstring1.3.2 Ana Santos Cranfield University1.4.1.1e2 Paul Jeffrey Cranfield University1.4.2.1 Visvanathan Lingamurti (Lingam) Pillay Durban University of Technology

Tim Young MBR Technology�1.4.2.2 David de Haas GHD Pty Ltd1.4.2.3 Xia Huang, Yuexiao Shen, Kang Xiao Tsinghua University1.4.2.4 Sebastian Zacharias Cinzac Group1.4.2.5 Hiroki Itokawa Japan Sewage Works Agency1.4.2.6 A. Wahab Mohammad Universiti Kebangsaan Malaysia1.4.2.7 Tao Guihe, Kiran Kekre, Harry Seah PUB1.4.2.8 Christoph Brepols Erftverband1.4.2.9 Victor Ferre Kubota Membrane Europe

Josef Dusini Ladurner Acque1.4.2.10 Darren Lawrence Koch Membrane Systems1.4.2.11 Daniel Sanchez Hera-AMASA

Victor Ferre Kubota Membrane Europe1.4.2.12 Stephen Kennedy Ovivo1.4.2.13 Zakir Hirani MWH Americas Inc.1.5 Ana Santos Cranfield University

1.1. DEFINITION

The term ‘membrane bioreactor’ (MBR) applies to all water and wastewatertreatment processes integrating a permselective membrane with a biologicalprocess. All currently available commercial MBR processes employ themembrane ostensibly as a filter, rejecting the solid materials developed by thebiological process to provide a clarified and disinfected product. It is this typeof MBR, the biomass rejection MBR (Section 1.1), which forms the primaryfocus of this book. The progress of technological development and marketpenetration of MBRs can be viewed in the context of their historical devel-opment (Section 1.2), current market penetration (Section 1.3), key drivers

The MBR Book.

Copyright � 2011 Elsevier Ltd. All rights reserved. 1

(Section 1.4) and the status of MBR research (Section 1.5), all impacting tosome degree on the future prospects of the technology (Section 1.6).

1.2. HISTORICAL PERSPECTIVE

1.2.1. Membranes and Membrane Technology

The membrane industry did not exist until the early twentieth century; the mainresearch on membrane separation phenomena was aimed at elucidating thephysico-chemical principles of the process, and the mechanism of diffusion.However, some of these early-stage achievements still impact on the academicresearch and industrial applications today. These include Fick’s (1855)phenomenological laws of diffusion, van’t Hoff’s (1887, 1888) osmotic pres-sure equation, for which he was awarded the first Noble Prize in Chemistry in1901, and Thomas Graham’s pioneering work in gas separation using bothporous membranes and dense membranes is still relevant today. Grahamdiscovered that rubber exhibits selective permeability to different gases, andalso found low-molecular weight substances to be concentrated in the perme-ated gas when the membrane pore size is close to the mean free path of gasmolecules (Graham, 1861, 1866). Graham’s work was inspired by Schmidt’s(1856) earlier study, where he had used bovine heart membranes (the poredimension being 1e50 nm) to separate soluble Acacia e arguably the firstdocumented ultrafiltration (UF) experiment.

The first synthetic UF membranes were prepared by Bechhold fromcollodion (nitrocellulose). Bechhold was also the first to measure membranebubble points, and to propose the term ‘ultrafilter’ (Bechhold, 1907). Otherimportant early researchers, Elford, Zsigmondy, Bachmann, and Ferry, etc.,further developed Bechhold’s membrane preparation method. Commercialapplication of collodion porous membranes can be attributed to Zsigmondy’slaboratory at the University of Goettingen, Germany; Zsigmondy and Bach-mann were the first to propose a method to produce porous collodion membranein an industrial scale (Zsigmondy & Bachmann, 1918, 1922). Based on thistechnology, the world’s first commercial microporous membrane supplier,Sartorius Werke GmbH, was established in Goettingen in 1925, although itsproducts were mostly sold to research laboratories. The early porous collodionmembrane formation method was named ‘dry inversion’, which is still in usetoday.

During World War II, damage to German distribution networks by bombingraids led to the development of techniques for rapid analysis for bacteria inwater supplies. Using Sartorius membranes, Muller and others at HamburgUniversity developed an effective method to cultivate micro-organisms indrinking water. This was the first large-scale application of microfiltration (MF)membranes. Following on from this work and in recognition of the strategicimportance of MF membranes, Alexander Goetz, a professor in the California

2 The MBR Book

Institute of Technology, was sponsored by the US military to duplicate theSartorius membrane technology. Goetz developed an improved membraneformation method, now called ‘vapour-induced phase separation’. The maininnovation of his method included using a copolymer of cellulose acetate andcellulose nitrate as the membrane material, and preparing the membrane ina high moisture environment. This technology was later transferred to LowellInc., and in 1954 Lowell established the Millipore Corporation to commer-cialise the membrane. This represents the incipient stages of the US micro-porous membrane industry.

The period between the 1960s and the 1980s is often regarded as being thegolden age of membrane science. The crucial breakthrough was the develop-ment of the asymmetric cellulose acetate membrane by Loeb and Sourirajan in1963 (Loeb & Sourirajan, 1964). Loeb and Sourirajan’s membrane preparationmethod is often referred to as ‘wet phase inversion’ or ‘non-solvent-inducedphase separation’ (NIPS). Microporous membranes prepared by this methodhave an asymmetric porous structure: a very thin surface microporous layer(w0.2 mm) supported by a substrate having larger pores. Because of its thinseparation layer, the NIPS membrane demonstrates significantly improvedfluxes.

The Loeb and Sourirajan membrane preparation method had a greatinfluence on the development of reverse osmosis (RO), UF, MF and gasseparation. Loeb and Sourirajan’s goal was focused on producing high-flux ROmembranes, but other researchers, particularly Alan S. Michaels, realized thegeneral applicability of the technique. Michaels was the founder of AmiconInc. In the 1960s, Amicon Inc. collaborated with Dorr-Oliver Inc. to developnew kinds of UF membranes prepared by using various polymers such aspolyacrylonitrile (PAN), polysulfone (PS), poly(vinylidene difluoride) (PVDF)and others (Michaels, 1963), applying the new products on an industrial scale.

Thermally induced phase separation (TIPS) represents another importantimprovement in the development of membrane technologies. In TIPS, polymerand its diluents are mixed under high temperature to form a uniform solution.Gradually reducing the temperature of the casting solution causes phaseseparation and consequently a porous structure. The first commercial TIPSmembrane may be attributed to Castro (1981). In the following two decades,TIPS membranes have been used in a variety of applications, such as bloodplasma filtration, membrane distillation, fuel cells and medical dressings.Advantages of TIPS membranes include high porosity, high permeation rate,high physical strength, narrow pore size distribution and greater water fluxesthan those of NIPS membranes: the pure water flux of typical TIPS MFmembranes commonly exceeds 1000 L per m2 membrane per hour per barpressure (LMH/bar), compared with 200e300 LMH/bar for NIPS UF and MFmaterials. TIPS membranes typically used for MF are of 0.1e0.4 mm pore size.

Two other commercially important membrane production methods are theradiation track etched and melt extrusion and cold-stretching methods.

3Chapter | 1 Introduction

Radiation track etching was developed in the 1960s (Fleischer, Price, &Walker, 1969) with limited application in the manufacture of flat membranedue to its poor permeability and high cost. The melt extrusion and cold-stretching method, on the other hand, is much lower in cost. The method wasfirst developed by Celanese Corp. in 1974 (Druin, Loft, & Plovan, 1974). In1977, Mitsubishi Rayon Corp. produced a hollow-fibre (HF) polyethylene (PE)MF membrane by this membrane formation method. As an immersedmembrane module, the HF PE MF membrane of Mitsubishi Rayon has foundmany applications in the field of wastewater treatment.

1.2.2. Membrane Bioreactor Technology

1.2.2.1. The Early Years: 1970se1990s

The first membrane bioreactors (MBRs) were developed commercially byDorr-Oliver in the late 1960s (Bemberis, Hubbard, & Leonardet, 1971),combining UF with a conventional activated sludge process (CASP), forapplication to ship-board sewage treatment (Bailey, Bemberis, & Presti, 1971).Other bench-scale membrane separation systems linked with a CASP werereported at around the same time (Hardt, Clesceri, Nemerow, & Washington,1970; Smith, Gregorio, & Talcott, 1969). These systems were all based on whathave come to be known as ‘sidestream’ configurations (sMBR, Fig. 1.1a), asopposed to the now more commercially significant ‘immersed’ configuration(iMBR, Fig. 1.1b). The Dorr-Oliver membrane sewage treatment (MST)process was based on flat-sheet (FS) UF membranes operated at what wouldnow be considered excessive pressures (3.5 bar inlet pressure) and low fluxes(17 L/(m2 h), or LMH), yielding mean permeabilities of less than 10 LMH/bar.Nonetheless, the Dorr-Oliver system succeeded in establishing the principle ofcoupling a CASP with a membrane to simultaneously concentrate the biomasswhilst generating a clarified, disinfected product. The system was marketed inJapan under license to Sanki Engineering, with some success up until the early1990s. Developments were also underway in South Africa which led to the

Out

Air

In

Out

Bioreactor

Membrane

Recirculated stream

Air

In

Sludge Sludge

(b)(a)

FIG. 1.1 Configurations of a membrane bioreactor: (a) sidestream and (b) immersed.

4 The MBR Book

commercialization of an anaerobic digester UF (ADUF) MBR by Weir Envig(Botha, Sanderson, & Buckley, 1992), for use on high-strength industrialwastewaters.

At around this time, from the late 1980s to early 1990s, other importantcommercial developments were taking place. In Japan, the government-insti-gated water recycling programme prompted pioneering work by Yamamoto,Hiasa, Mahmood, & Matsuo (1989) to develop an immersed HF UF MBRprocess, as well as the development of an FS-microfiltration iMBR by theagricultural machinery company, Kubota (Section 4.2.1). This subsequentlyunderwent demonstration at pilot scale, first at Hiroshima in 1990 (25 m3/day,or 0.025 megalitres per day or MLD) and then at the company’s own site atSakai-Rinkai in 1992 (0.110 MLD). By the end of 1996, there were already 60Kubota plants installed in Japan for domestic wastewater and, later on,industrial effluent treatment, providing a total installed capacity of 5.5 MLD.Also in Japan, Mitsubishi Rayon introduced its SUR MBR membrane module,based on its Sterapore product, in 1993.

Both these products to some extent displaced some of the older sidestreamsystems which had been established in Japan, though side-stream MBRscontinue to be used in Japan and elsewhere. The installation of in-buildingwastewater recycling plants in Japan based on the Orelis Environment(formerly Rhodia Orelis and before this Rhone Poulenc) PLEIADE� FS sMBRsystem, actually pre-dates that of the Kubota plants for this duty. ThePLEIADE� system was originally trialled in France in the 1970s and by 1999there were 125 small-scale systems (all below 0.2 MLD) worldwide, themajority of these being in Japan and around a dozen in France. The Dorr-OliverMST system was similarly rather more successful in Japan than in NorthAmerica in the 1970s and 1980s (Sutton, Mishra, Bratby, & Enegess, 2002).Wehrle Environmental, part of the very well-established Wehrle Werk AG(formed in 1860) of Germany, has been applying its multitube (MT) sMBRs(predominantly employing Norit X-Flow polymeric MT membrane modules)to landfill leachate treatment since 1990. A sidestream MBR Degremontsystem based on ceramic membranes was introduced in the mid-1990s, andother ceramic membrane products have also been employed in a few sMBRapplications. These pumped sidestream systems all tend to be used for indus-trial effluent treatment applications involving relatively low flows, such thattheir market penetration compared with the immersed systems, particularly inthe municipal water sector, has been limited.

At around the same time as Kubota were developing their product, in theUSA Thetford Systems were developing their Cycle-Let� process, anothersidestream process, for wastewater recycling duties. Zenon Environmental,a company formed in 1980 and who subsequently acquired Thetford Systems,were developing an MBR system. By the early 1990s, the ZenoGem�immersed HF UF MBR process had been patented (Tonelli & Canning, 1993;Tonelli & Behmann, 1996), and the first immersed HF ZeeWeed� module, the


ZW145 which provided 145 square feet of membrane area, was introduced tothe market in 1993 (Section 4.3.1). By the end of the Millennium the totalinstalled capacity of Zenon plants had reached 150 MLD.

1.2.2.2. The Late 1990s Onwards: the Developmentof Other MBR Products

The first Kubota municipal wastewater treatment works installed outside Japanwas at Porlock in the United Kingdom in 1997 (Section 5.3.1.1), followingsuccessful trials at Kingston Seymour by Wessex Water in the mid-1990s. Thefirst Zenon membrane-based plant of similar size installed outside of the USAwas the Veolia (then Vivendi) Biosep� plant at Perthes en Gatinais in France in1999 (Section 5.3.1.1). Both these plants have a peak flow capacity just below2 MLD, and represent landmark plants in the development and implementationof immersed MBR technology.

By the late 1990s, however, other MBR membrane products and systemswere under development, leading to an explosion of commercial activity fromthe turn of the Millennium to the present day. Whereas the first half of the1990s saw the launch of only three major immersed MBR membrane prod-ucts, originating from just two countries (USA and Japan), the first five yearsof the following decade saw the launch of at least 10 products originatingfrom seven countries, coupled with three significant acquisitions in the mid-noughties (Section 1.3). For 12 major suppliers (Table 1.1) as at 2010, therewere either existing or planned MBR installations of more than 10 MLDcapacity. In addition to those products listed for which there are ‘flagship’large plants, there are currently at least another 33 MBR membrane products(Chapter 4), all of which have come to the market since around 2000, inaddition to a number of proprietary MBR technologies based on a few of themembrane products.

1.3. MARKET

1.3.1. General

MBR systems have been implemented in more than 200 countries (Icon,2008); growth rates and the extent of implementation vary regionallyaccording to the state of economic development and infrastructure. Commonto all regions, however, is the fact that sales of the technology havegenerally grown faster than the GDPs of countries installing them, signifi-cantly so in China, as well as more rapidly than the industries that use them(Srinivasan, 2007; BCC, 2008). Global growth rates between 9.5 and 12%are routinely quoted in reports produced by market analysis, and the marketvalue of the MBR industry is predicted to approach $0.5 billion ($500million) by 2013. Data taken from two sources for the period between 2000and 2013 indicate a mean growth rate of 11.6e12.7% (Fig. 1.2). These data

6 The MBR Book

also suggest that growth may be slow marginally in the period between 2010and 2015 due to the global economic downturn. The difference in absolutevalues between the two studies reflects differences in assumptions maderegarding eligible costs and income. It has been suggested in another report,for example, that the global membrane bioreactors (MBRs) market willreach $1.3 billion by 2015 (GIA, 2009).

1.3.2. Suppliers

A review of the share of the municipal market across the MBR membraneproduct suppliers reveals it to be still dominated by the original threesuppliers (Fig. 1.3), with Kubota providing around 20e25% of the totalnumber of MBR installations for the top 11 MBR membrane providers (with

TABLE 1.1 MBR Membrane Module Products, Bulk Municipal Market

Supplier Country

Date

launched Acquired

Date, first

>10 MLD plant

Asahi Kasei Japan 2004 e 2007

GE- ZeeWeed� USA 1993 Jun-06 2002

Korea MembraneSeparation-KSMBR�

Korea 2000 e 2008

Koch MembraneSystems e PURON�

USA 2001 Nov-04 2010*

Kubota EK Japan 1990 e 1999

Kubota RW Japan 2009 e

Memstar Singapore 2005 e 2010*

MICRODYN-NADIR Germany 2005 e 2010*

Mitsubishi Rayon (SADF) Japan 2005 e 2006

Mitsubishi Rayon (SUR) Japan 1993 e

Motimo China 2000 e 2007

Norit Netherlands 2002 e 2010*

Siemens Water Tech.eMEMCOR�

Germany 2002 Jul-04 2008

Toray Japan 2004 e 2010*

*Projected 2010 or 2011.


respect to installed capacity) and GE Zenon more than 40% of the totalglobal installed capacity for MBR treatment. Mitsubishi Rayon Engineering(MRE) have an estimated similar number of municipal installations toKubota, with their activities largely limited to the Far East. However, newerMBR membrane products are increasing in number and market share. As

y = 5E-99e0.1155x

R² = 0.9921

y = 7E-109e0.1272x

R² = 0.9821

100

1000

2000 2002 2004 2006 2008 2010 2012

Glo

ba

l m

arket valu

e, $m

Date

BCC F&S

FIG. 1.2 MBR global market value in $bn; data taken from Frost and Sullivan and BCC reports.

(Srinivasan, 2007; BCC, 2008).

0

200

400

600

800

1000

1200

1400

1600

1800

2000

Kubo

ta

Tora

y

Wei

se

Hub

er

GE

Zeno

n

Mits

ubis

hi R

ayon

*

Koch

Pur

on

Siem

ens

Mem

cor

Asah

i Kas

ei

KMS

Kore

a

Nor

it*

MTHFFS

Nu

mb

er a

nd

in

sta

lle

d c

ap

ac

ity

o

f m

un

ic

ip

al M

BR

in

sta

lla

tio

ns

Capacity, MLDNo. plants

FIG. 1.3 MBR municipal market; *estimated figures from available information ( from Santos

and Judd, 2010).

8 The MBR Book

recently as 2003, the three most established players of Kubota, MitsubishiRayon and Zenon held 85e90% of the municipal MBR market, with around800 installations between them (Pearce, 2008). By the end of 2009 the totalnumber of installations provided by these three suppliers had risen to around4400, with at least 32 other membrane suppliers with wastewater treatmentMBR reference sites and a total number of MBR membrane module productsapproaching 60 (Fig. 1.4).

A review of the geographical location of the MBR membrane modulesuppliers (Fig. 1.5) reveals them to derive primarily from East Asia, with China,Korea and Japan accounting for more than half of the 45 MBR membraneproduct suppliers identified by May 2010, and the EU nations, and principallyGermany, providing much of the remainder. Moreover, there are more suchproducts either currently close to being commercialized or else alreadycommercially available but not visible through the usual routes of internet

0

10

20

30

40

50

60

1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010

Nu

mb

er o

f p

ro

du

cts

Year

FIG. 1.4 Number of MBR membrane module products.

China & Taiwan27%

Korea14%Japan

14%

Germany18%

Rest of Europe18%

North America4%

Singapore5%

FIG. 1.5 MBR membrane product suppliers by geographical location.


search engines, international trade shows or articles/advertisements in trademagazines. Whilst it is not always possible to distinguish between originalmembrane or membrane module manufacturers (i.e. original equipmentmanufacturers, or OEMs) and those which acquire these products and rebrandthem for sale, it is apparent that many of these products are discrete andestablishing a market either by geographical region or industrial sector. It isalso the case that the majority of the commercially available iMBR membrane

TABLE 1.2 The 20 Largest MBR Plant (May 2010)

Project Technology Date PDF MLD

Shending River, China BOW 2010 120

Wenyu River, China Asahi K/BOW 2007 100

Johns Creek, GA GE Zenon 2009 94

Beixiaohe, China Siemens 2008 78

Al Ansab, Muscat, Oman Kubota 2010 78

Peoria, AZ GE Zenon 2008 76

Cleveland Bay, Australia GE Zenon 2007 75

Sabadell, Spain Kubota 2009 55

San Pedro del Pinatar, Spain GE Zenon 2007 48

Syndial, Italy GE Zenon 2005 47

Broad Run WRF, VA GE Zenon 2008 47

Beijing Miyun, China MRE 2006 45

NordKanal, Germany GE Zenon 2004 45

Tempe Kyrene, AZ GE Zenon 2006 44

Brescia, Italy GE Zenon 2002 42

Traverse City, MI GE Zenon 2004 39

Linwood, GA GE Zenon 2007 38

North Kent Sewer Authority, MI GE Zenon 2008 35

Jinqiao Power, China GE Zenon 2006 31

Dubai Sports City, UAE GE Zenon 2009 30

PDF, Peak daily flow; MLD, Megalitres per day; BOW, Beijing Origin Water; and MRE, Mitsubishi

Rayon Engineering.

10 The MBR Book

Documents

· these was the original book on membrane bioreactors: Membrane Bioreactors for Wastewater Treatment by Tom Stephenson, Simon Judd, Bruce Jefferson and Keith Brindle, which came