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Upgrading and retrofitting of municipal

wastewater treatment plants by means of
membrane bioreactor (MBR) technology
ARTICLE in DESALINATION OCTOBER 2008
Impact Factor: 3.96 DOI: 10.1016/j.desal.2007.11.035

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Desalination 231 (2008) 2026

Upgrading and retrofitting of municipal wastewater treatment

plants by means of membrane bioreactor (MBR) technology
Ch. Brepolsa, E. Dorgelohb, F.-B. Frechenc, W. Fuchsd, S. Haidere, A. Jossf,
K. de Korteg, Ch. Ruikeng, W. Schierc*, H. van der Roesth, M. Wetti, Th. Wozniakj
a
Erftverband, Bergheim, Germany
Prf- und Entwicklungsinstitut fr Abwassertechnik (PIA) an der RWTH Aachen, Germany
c
Department of Sanitary and Environmental Engineering - DESEE, University of Kassel, Germany
Tel. +49 (561) 8043817; Fax +49 (561) 8043642; email: wernfried.schier@uni-kassel.de
d
University of Natural Resources and Applied Life Sciences Vienna, Department IFA-Tulln,
Institute for Environmental Biotechnology, Tulln, Austria
e
H2Office Abwassertechnik, Wien, Austria
f
EAWAG Swiss Federal Institute of Aquatic Science and Technology, Duebendorf, Switzerland
g
DWR Dienst Waterbeheer en Riolering, Amsterdam, The Netherlands
h
DHV Consultancy and Engineering, Amersfoort, The Netherlands
i
Sddeutsche Abwasserreinigungs-Ingenieur GmbH, Ulm, Germany
j
wws consulting, Reutlingen, Germany
b

Received 17 May 2007; accepted revised 20 November 2007

Abstract
In the future, upgrading of existing wastewater treatment plants (wwtps) will become the more challenging task
than erection of wholly new plants, as most of the plants (e.g. necessary in Germany) do exist already. Since some
time, MBR technology has been taken into consideration and has been realised as an alternative for wwtp upgrading.
This paper gives an overview about some relevant preconditions, basic upgrading concepts and examples of already
upgraded wwtps using MBR technology.
Keywords: Municipal wastewater treatment; Upgrading; MBR technology

*Corresponding author.
Presented at The 4th IWA Conference on Membranes for Water and Wastewater Treatment
May 1517, 2007, Harrogate, UK
0011-9164/08/$ See front matter 2008 Elsevier B.V. All rights reserved

Ch. Brepols et al. / Desalination 231 (2008) 2026

1. Introduction
Many wwtps suffer from an inadequate level
of treatment provided. There are several reasons
for the need of retrofitted and/or upgraded equipment, such as expiry of lifespan, the increase of
wastewater flow or load or higher treatment standards due to a change of legal framework. In general, no standard solutions for the upgrading of
wastewater treatment systems are available and
the transfer of a certain measure from one case to
another is limited. In fact, the optimum answer in
each individual case is largely site-dependent.
Accordingly, there is a broad spectrum of measures that might be employed. In most cases it is
not a singular action to be taken, but the upgrading will incorporate a set of different interlocking
components both at the drainage system and the
wastewater treatment plant.
The MBR process is an emerging advanced
wastewater treatment technology that has been
successfully applied at an ever increasing number of locations around the world. It involves a
suspended growth activated sludge system that
utilizes microporous membranes for solid/liquid
separation as a substitute of the conventional secondary clarifier. MBR technology has not only
attracted increasing interest for the set up of new
wastewater treatment systems but also it has high
potential looking at upgrading tasks of already
existing wwtps.
2. Considerations for the choice of MBR
technology
Since membrane filtration allows raised sludge
concentrations, the activated sludge tank volume
can be significantly reduced. In combination with
the option to convert the secondary clarifier, that
is no longer required as a sedimentation tank, as
an additional activated sludge tank, the treatment
capacity of the existing plant can be largely extended. That way it is possible to upgrade existing wwtps from simple carbon removal to BNR
systems just using the already existing volume.

21

Therefore favourable conditions for the choice

of MBR technology are given, where retrofitting
of the existing plant by the conventional activated
sludge (CAS) process would demand for substantial extension of the activated sludge volume. As
well, where limitations due to insufficient efficiency of the secondary clarification basin exist,
particularly however, where both problems have
to be solved.
MBR technology should also be considered if
high effluent criteria such as removal of suspended
solids or absence of pathogens have to be met.
Examples are discharge into small creaks as well
as into bathing water or other sensitive areas.
Due to the small space requirement the MBR
offers special advantages if the given location
holds no or only a limited amount of area in reserve. Moreover, the small footprint allows a complete indoor installation in a building designed to
blend in with its surrounding environment and
such to address issues of visual amenity, odour or
noise.
Another distinct advantage of MBR technology is direct utilisation of the effluent for reuse
purposes. The water reuse potential includes irrigation of agricultural land, recharge of aquifers
or river flow replenishment. On several occasions
this was the major decision criteria to opt for MBR
technology.
With the choice of the MBR special attention
should be paid to the fact that the investment costs
are largely correlated with the hydraulic peak flow.
This parameter determines the total membrane
surface area which needs to be installed. Therefore, accompanying measures to minimize wet
weather flow or to harmonise resultant wastewater largely contribute to cost effectiveness of the
MBR approach. One option for dealing with high
wet weather peaks is to use the former secondary
clarifier as storage volume. Another option is hybrid systems where the conventional system is
used as a backup to treat the inflow volume that
exceeds the hydraulic membrane capacity. An already realised hybrid concept designs the MBR

22

Ch. Brepols et al. / Desalination 231 (2008) 2026

line to treat the dry weather flow at the maximum.

The inflow volume beyond dry weather conditions is treated conventionally.
3. Modification of the operation mode using
the MBR approach
With the change of sludge/treated wastewater
separation from gravity settling to membrane filtration the following process configurations are
available:

ing sedimentation tanks can be included sensibly

in the future concept of utilisation. According to
the structural state it can be possible to use these
tanks as an additional biological volume. Also the
suitable installation and operation of the membrane modules either in activated sludge tanks or
in separated filtration chambers depends on the
quality of the respective structural situation. At
this point wide engineering space is given. Fig. 1
shows some possible variations.
3.2. Hybrid systems

3.1. MBR with or without a separate filtration

chamber
With upgrading of wwtp as a pure MBR process the question is to be cleared whether exist-

The combination of the CAS process and the

MBR process is understood as the hybrid procedure. Fig. 2 shows two basic operation concepts
of hybrid processes (among other hybrid systems).

initial situation
sed.
tank

biology

A: substitution of the sedimentation tank by a separate filtration chamber

biology

FC

B: sedimentation tank: change of utilisation as biological volume

biology

biology

FC

C: change of flow scheme and immersed membranes within the biology

biology

Fig. 1. Upgrading variations using MBR technology.

biology

Ch. Brepols et al. / Desalination 231 (2008) 2026

23

parallel
sed.
tank

biology

biology

FC

serial
peak flow

biology

sed.
tank

biology

FC

Fig. 2. Basic operation concepts of the hybrid procedure.

Besides, a fullness of mixing variations is possible. The flow concept of the sludge streams between both biological units at parallel operation
mode or serial operation mode can be operated
separately or combined according to the local circumstances (grey arrows in Fig. 2). In the latter
case possible differences are to be taken into consideration concerning the sludge qualities, in particular, the quality of sedimentation and the MLSS
concentrations.
3.3. Other processes
Beside the combination with the CAS process
also combinations with other wastewater treatment procedures are possible, e.g. with SBR technology [1] or with pond technology. Today SBR
technology integrating membrane technology as
separation process is used at industrial applications or at package plants. Applications combining pond technology and MBR technology are op-

erated at wwtp St. Peter ob Judenburg, Austria

and at wwtp Ihn, Germany.
3.4. MBR process with low MLSS concentration
In cases when available sedimentation volume
is used as additional biological volume, the
amount of total biological volume increases to a
degree, that clearly exceeds the usual volume demand of a conventional MBR process with appropriate MLSS concentrations ranging from
10 kg/m to 15 kg/m. Dimensioning the MLSS
concentration both the available biological volume and the guarantee of the aerobic SRT have to
be taken into consideration. Usually this dimensioning ends up with less MLSS concentration in
the range of 57 kg/m [2,3] compared with conventional MBR operating circumstances. If such
a draught can be realised, the usual disadvantages
(sensibility compared to impact load, reduced alpha value) could be overcome by MBR process

24

Ch. Brepols et al. / Desalination 231 (2008) 2026

to a great extent. Beside the anyway raised effluent quality other advantages of this upgrading
concept can be named:
considerable biological reserve capacities for
future extension;
smaller place consumption compared to a conventional upgrading concept.
Some manufacturers of membrane modules
recommend not falling short of a given MLSS
concentration directly at the membrane or within
a separated filtration chamber. Thus, the suitability of the respective membrane modules for the
low MLSS operation mode is to be clarified.
Nevertheless, by the construction of a separate
filtration chamber optimal MLSS concentrations
at the membrane and within the biological zone
can be adapted accordingly.
3.5. MBR in combination with anaerobic sludge
stabilization
Up to now most municipal MBR plants are
dimensioned with aerobic simultaneous sludge
stabilization. In principle the MBR process also
can be combined with anaerobic sludge stabilization. Some single studies assume dependence between increasing fouling potential and increasing
F/M-ratio or rather decreasing SRT [46]. A final
statement cannot be met yet. If the MBR process
is dimensioned with a short SRT, hence, possible
intensified fouling effects have to be considered.
If the MBR process is dimensioned with a long
SRT, slightly reduced digester gas production can
be expected. A possible process variation features
the digestion of only primary sludge. Thus, in an
upgrading situation the cost intensive new building of digestion volume can be avoided.
4. Experiences from full-scale applications
The full version of DWA WG KA-7.4 report
includes all subsequently mentioned wwtps:
wwtp St. Peter ob Judenburg, Austria
wwtp Schilde, Belgium

wwtp Eitorf, Germany

wwtp Bergheim-Glessen, Germany
wwtp Brescia, Italy
wwtp Viareggio, Italy
wwtp Heenvliet, Netherlands
wwtp Rietliau, Switzerland

Upgrading of wwtps by means of MBR technology is not a question of special membrane

types. The above mentioned plants are equipped
with usual and well known hollow fibre membranes as well as with flat sheet membranes.
In the following two plants out of the above
mentioned are now introduced more detailed.
Besides, the German wwtp Bergheim-Glessen is
an example for a complete process rearrangement.
The Swiss wwtp Rietliau shows a hybrid solution.
4.1. wwtp Bergheim-Glessen, Germany
In the case of the wwtp Bergheim-Glessen
MBR technology is used to meet advanced requirements caused by the discharge of wastewater to sensitive wetland. Upgrading occurs at the
existing location using extensively already existing constructions. Treatment efficiency will be
rapidly increased by introducing MBR technology. Hence, in addition, the wastewater of a
neighbouring, smaller wwtp, likewise in the need
of upgrading, is led across, treated and afterwards
led back. Thus, the wwtp load is raised from
5,000 p.e. nowadays to 9,000 p.e. Wastewater
quantity to be treated from now on amounts to
900,000 m/a. Fig. 3 illustrates the flow diagram.
The mechanical pre-treatment is completely
renewed consisting of three units: screening (gap
size 6 mm), aerated grit chamber and grease trap,
sieving (mesh geometry, gap size 1 mm). The
existing oxidation ditch furthermore will be used
as activated sludge volume. SRT should amount
about 25 d, MLSS concentration is dimensioned
with only 8 kg/m. In time of maximum inflow
HRT amounts to 6 h. The membrane modules are
installed in four separated filtration chambers.

Ch. Brepols et al. / Desalination 231 (2008) 2026

25
FC

screen
6 mm

grit chamber,
grease trap

sieve
1 mm

activated sludge tank

(former oxidation ditch)

FC
FC

DN / N

FC

concentrate

storage tank,
former secondary
clarifier

Fig. 3. Flow diagram of wwtp Bergheim-Glessen.

Sludge treatment and simultaneous precipitation

are taken over from the todays continuance. The
plant is scheduled to be commissioned in late
2007.
4.2. wwtp Rietliau, Switzerland
Upgrading was necessary to meet the effluent
requirements (DOC: 10 mg/l, BOD: 10 mg/l, P
total: 0.2 mg/l, SS: 5 mg/l) especially according
parameter SS which was unachievable by the
former wwtp concept. An upgrading of the treatment capacity from 41,400 p.e. up to 44,000 p.e.
also would have been accomplished by depth filtration as a fourth treatment step. Caused by small
space availability the hybrid solution was evaluated as an economically more favourable way.
Shortage of space is due to the wwtp location in
the midst of the residential area Wdenswil, 100 m
far from the bank of the Lake of Zurich. Fig. 4
shows the flow diagram.
Wwtp Rietliau was commissioned in November 2005. The treatment process is subdivided into
two lines. Each, the MBR line and the conventional process line, treat half of the incoming
wastewater. Sludge of both treatment lines is not
mixed. All wastewater is treated by the existing
mechanical pre-treatment units (screen, grit chamber and grease trap, primary sedimentation). In
addition, the inflow from the primary sedimentation to the MBR line is led through a sieve consisting of hole geometry with 1 mm gap size.

The MBR line consists of two sub-lines. Aerobic and anoxic volumes of the MBR process are
dimensioned the way, that in times of maximum
inflow the minimum HRT within the biological
zone prior to the filtration chambers does not fall
below 30 min.
Better effluent quality concerning the conventional process line also is achieved caused by the
less hydraulic load of the secondary clarifiers.
Thus, the requirements that have to be met by the
mixture of both effluent streams can be guaranteed.
5. Conclusions
The presented upgrading concepts raise no
claim to completeness and thus reveal the wide
spectrum of supposable measures. Many of them
are under investigation and appropriate findings
can be expected to be reported soon. However,
the chosen upgrading concept must meet the claim
to be
demand-oriented according the wastewatersided requirements and the load situation,
economical in view of annual costs (operating
expenses and net debt service).
Besides, various other, not only process-related, but also nonmonetary and monetary hardly
assessable aspects are to be followed and to weigh
in each individual case which do not admit a stan-

26

Ch. Brepols et al. / Desalination 231 (2008) 2026

conventional activated sludge process
return sludge
BOD

sec.
sed.

BOD

sec.
sed.

prim.
sed.

50%
return sludge
screen
6 mm

grit chamber,
grease trap

MBR process
concentrate

50%
sieve
1 mm

DN / N
(existing)

FC

sieve
1 mm

DN / N
(existing)

FC

prim.
sed.

concentrate

Fig. 4. Flow diagram of wwtp Rietliau.

dard approach concerning the handling of the

planning task.
Altogether MBR technology provides several
promising perspectives in view of upgrading
wwtps. The different options introduced provide
an overview of the bunch of possibilities the optimal solution can be selected from. As with all
other upgrading options which in general are individual solutions, special importance lies on the
adequate diligence of the planning engineer. Nevertheless the increasing number of full scale applications presents a sound and ever growing decision basis.
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