Integrated DAF-MBBR technology

By: Kate Chen
Email: [email protected]
Date: Mar 13th, 2025

The integrated DAF-MBBR technology achieves efficient purification of complex wastewater through the synergistic effects of "physicochemical pretreatment + biological treatment."

I. Technical Principles and Synergistic Mechanisms

Physical Separation by DAF

Core Function: Microbubbles (<10 μm) adsorb suspended solids, oils, colloids, and other pollutants for rapid flotation separation (SS removal >95%, oil removal >90%).

Key Applications: Ideal for high-suspended solids and high-oil wastewater (e.g., refinery, food processing, slaughterhouse wastewater), reducing biological treatment load downstream.

Biological Degradation by MBBR

Biofilm Carrier Role: High-surface-area (2,000–3,000 m²/m³) suspended carriers support biofilm growth (300–500 μm thick), enhancing shock load tolerance by 50%.

Efficient Carbon/Nitrogen Removal: Multi-stage reactors (e.g., A/O-MBBR) enable simultaneous nitrification-denitrification (COD removal >90%, ammonia removal >85%).

Synergistic Effects

Pollutant Cascade Removal: DAF removes suspended solids and oils first, preventing biofilm clogging; MBBR degrades dissolved organics and ammonia.

Energy Optimization: DAF pretreatment reduces MBBR aeration energy consumption (~20–30%), lowering overall carbon emissions by >15%.

II. Key Operational Parameters and Performance Data

Process Stage	Optimized Parameters	Removal Efficiency (Typical)	Data Source
DAF Unit	Flotation time: 10 min, Airflow: 72 L/min	COD: 61.3%, Oil: 97.6%, TSS: 76%	Industry Case Studies
MBBR Unit	HRT: 23.5 h, Mixing time: 13–23 min	COD: 47–73%, Ammonia: 94.9–97.9%	Lab Trials
Integrated Process	Aeration intensity: 4.5–6.0 m³/(m²·h)	Effluent COD <30 mg/L, NH3-N <5 mg/L	Field Tests

III. Application Scenarios and Case Studies

Oil Refinery & Petrochemical Wastewater

Case: A refinery adopted DAF-MBBR for oily wastewater treatment. After DAF removed 97% of oil, MBBR reduced COD from 1,500 mg/L to <50 mg/L, with 40% less sludge production.

Technical Fit: DAF separates oil droplets (>10 μm), while MBBR degrades dissolved hydrocarbons (e.g., benzene derivatives).

Food Processing Wastewater

Case: A meat processing plant used DAF (with 30 mg/L PAC dosing) for high-TSS wastewater pretreatment. MBBR achieved 93% COD removal at HRT 6 h, with a 60% smaller footprint than conventional systems.

Cost Savings: 25% lower operating costs due to reduced chemical usage and sludge disposal.

Municipal Wastewater Upgrading

Pilot Results: DAF-MBBR achieved effluent COD <20 mg/L and TP <0.3 mg/L (meeting China’s Grade 1A standards) without expanding existing tanks.

Scalability: Modular design enables rapid deployment for decentralized rural treatment.

IV. Technological Innovations

Smart Control Systems

IoT Integration: Real-time DAF microbubble adjustment (via pressure sensors and AI) and MBBR biofilm activity monitoring (e.g., ATP sensors) for dynamic optimization.

Case: A project reduced energy use by 18% via PLC-controlled DAF-MBBR linkage.

Material Advancements

DAF Nanotech: Nano-ceramic diffusers boost bubble generation efficiency by 30% and lifespan to 8 years.

MBBR Carrier Modifications: Magnetic nanoparticle (Fe3O4)-coated carriers accelerate biofilm formation by 50% and enhance toxin resistance.

Chemical-Free Operation

Zero PAC/PAM Mode: Micro-nano bubble-enhanced DAF separation (e.g., cyclone dissolution) combined with endogenous denitrification in MBBR eliminates chemical dosing.