Process Intensification (PI) is an emerging technology in wastewater treatment that can improve the performance of existing infrastructure or reduce the capital costs of expansions with less infrastructure requirements. Process Intensification involves techniques that can enhance existing process capabilities, such as simultaneous nitrification-denitrification, 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 and promoting nutrient removal, and may include incorporating fixed film systems and/or densification.
Densification Densification focuses on improving solids separation, including sludge settleability and clarifier or membrane loading. Densification can also improve biological characteristics and diversity and thus may provide the benefits of intensification.
The Benefits of Process Intensification
Process Intensification can yield several benefits:
- Enhanced nutrient removal capabilities.
- Improved sludge settleability and reduced filamentous bulking and foaming.
- More robust and tolerant biology to loading and temperature fluctuations.
- Increased capacity for organic loading within the same footprint.
- 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. MBRs are 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 hydrocyclones.
- Densification: This technology typically 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. It is typically more successful if anaerobic selectors are available.
- 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 or ballasted settling technology by improving settleability.
- Aerobic granular sludge benefitsThis 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 most applications, particularly industrial facilities, the implementation of PI will most likely 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!
