Making the Most of Wastewater Infrastructure: An Introduction to Process Intensification

Process Intensification (PI) is an emerging technology in wastewater treatment that can improve the performance of existing infrastructure. Although PI is gaining traction in municipal systems, it remains relatively new in the industrial wastewater space and would require pilot studies before full-scale implementation.

What is Process Intensification?

Process Intensification involves techniques that can enhance existing process capabilities (such as simultaneous nitrification-denitrification or biological phosphorus removal), facilitate increased capacity within the same footprint, and improve settling and filament control.

Intensification vs. Densification

Intensification and Densification can have overlapping approaches and benefits.

Intensification typically relates to improving biological characteristics – such as increasing microbial diversity and robustness, promoting nutrient removal, and may include incorporating fixed film systems and/or densification.

Densification focuses on improving solids separation, including sludge settleability and clarifier or membrane loading. Densification can also improve biological characteristics and thus may provide the benefits of intensification.

The Benefits of Process Intensification

Process Intensification can yield several benefits:

• Enhanced nutrient removal capabilities.
• Increased capacity for organic loading within the same footprint.
• Improved sludge settleability and reduced filamentous foaming.
• Reduced capital costs with smaller expansions needed.

Top Technologies for Wastewater Process Intensification

• Membrane Bioreactor (MBR): An MBR offers a well-established technology with high-quality effluent through the use of ultrafiltration membranes. But MBRs are also a type of process intensification as they facilitate higher mixed liquor concentrations, approximately 10,000 mg/L, which can double the biological treatment capacity in existing tanks. They do not provide densification of biomass on their own, but this can be added with a hydrocyclone.
• Densification: This technology utilizes hydrocyclones and can easily be added to existing or new processes to significantly improve solids settling and separation performance, minimize foaming, and may provide biological process improvements.
• Organic Based Biological Fixed Film: Organic based biomass carriers can be used to enhance mixed liquor biomass communities (floc), their robustness, nutrient removal and intrinsically can perform like a densification technology by improving settleability.
• Aerobic Granular Sludge: This intensification technique uses unique process control and operational strategies to select for and develop a higher level of densified biological floc, aka granular sludge. These granular floc can simultaneously achieve high performing biological nutrient removal and greatly enhanced solids settling performance.

Overcoming Challenges in Process Intensification

For industrial facilities, the implementation of PI will require pilot testing to validate performance. Other barriers include high capital investment for certain technologies and the need for advanced operational expertise. However, these challenges can be overcome through phased implementation, targeted technology selection, and close collaboration with experienced engineering partners. Facilities must also consider site-specific constraints, existing infrastructure, and long-term operational goals when selecting PI strategies.

Transforming Wastewater Treatment for the Future

Process Intensification represents a transformative approach to wastewater treatment, enabling increased capacity and performance within existing infrastructure. While municipal applications are more common, industrial facilities stand to gain significant advantages by adopting these technologies. From biological enhancements to advanced solids separation, the integration of intensification and densification strategies can drive efficiency, enhance existing infrastructure, and meet growing regulatory demands.

Ready to Enhance Your Wastewater Treatment?

If your facility is exploring ways to expand capacity or improve treatment performance, now is the time to consider Process Intensification. Our team of wastewater experts can help you evaluate your current systems, design a customized strategy, and implement solutions that deliver results. Contact us today to get started!