Integrated Flat-Sheet MBR Membrane Bioreactor Technical Report (Capacity: 10 Tons/Day)
1. Technical Principles & System Configuration
1. Core Mechanism
The integrated MBR (Membrane Bio-Reactor) combines biological degradation with membrane separation technology. Flat-sheet membrane modules achieve efficient sludge-water separation. Microorganisms degrade organic pollutants in the bioreactor, while the membrane pores (0.1-0.4μm) retain suspended solids, bacteria, and macromolecules, ensuring effluent quality meets or exceeds China's Grade 1A Standard (GB18918-2002).
2. System Components
- Pre-treatment Unit: Screens for coarse particles; equalization tank for water quality/quantity stabilization.
- Bioreactor: Utilizes activated sludge processes (e.g., A²O or SBR) for carbon removal, nitrification, and phosphorus elimination, with MLSS (Mixed Liquor Suspended Solids) maintained at 8-12g/L.
- Flat-Sheet Membrane Modules: Made of anti-fouling PVDF material, optimized inter-membrane spacing (5-8mm), single-module surface area 20-30M2 designed flux 10-15 LMH (Liters per m²·Hour).
- Smart Control System: PLC-based automation with real-time monitoring (DO, pH, TMP) and automated backwash/cleaning cycles.
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2. Advantages of Flat-Sheet MBR Technology
1. Anti-Fouling Performance
High surface flow velocity (0.3-0.5m/s) and intermittent aeration (2:1 aeration/idle ratio) reduce membrane fouling, extending chemical cleaning intervals to 3-6 months (1/3 the frequency of hollow-fiber membranes).
2. Modular Scalability
Each membrane cassette handles 1-2 tons/day; a 10-ton system uses 5-8 parallel modules for flexible expansion. Individual membrane sheets can be replaced, cutting maintenance costs by 40%.
3. Robust Mechanical Strength
Polypropylene (PP) grid support layer withstands pressure fluctuations (0.01-0.05MPa) and high SS (≤50mg/L) conditions.
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3. Design Specifications for 10-Ton/Day System
| Parameter | Value | Remarks |
|-------------------------|-------------------------|--------------------------------------|
| Treatment Capacity | 10m³/day | 24-hour continuous operation |
| Total Membrane Area | 150-200M | Flux: 12 LMH |
| Aeration Demand | 0.8-1.2m³/min | Rotary shear aerators, ≤0.8kW energy |
| Effluent Quality | COD≤30mg/L, NH-N≤5mg/L | Exceeds GB18918-2002 Grade 1A |
| Footprint | 15-20M | Containerized integrated design |
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4. Applications & Economic Benefits
1. Typical Use Cases
- Decentralized Rural Wastewater: Adapts to flow variations; no sewer networks required.
- Food Processing Effluent: Treats high-COD (2000-5000mg/L) oily wastewater.
- Hospital Wastewater: Removes pathogens, replacing chlorine disinfection.
2. Cost Analysis
- Capital Investment: ~RMB 250,000-350,000 (including civil works).
- Operational Cost: Energy RMB 0.6-0.8/ton; chemicals RMB 0.2/ton; membrane lifespan 5-8 years.
- ROI: Saves 50% space and 60% labor compared to conventional systems.
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5. Key Operational Guidelines
1. TMP (Transmembrane Pressure) Control
Alarm threshold ≤25kPa; automated cleaning with citric acid (0.1-0.5%) and sodium hypochlorite.
2. Sludge Concentration Management
Maintain F/M (Food-to-Microorganism) ratio at 0.05-0.1kgCOD/kgMLSS·d via sludge discharge pumps.
3. Winter Operation
Bioreactor insulation (polyurethane foam) ensures water temperature ≥12°C for stable nitrifier activity.
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6. Future Innovations
1. Low-Carbon Upgrades
Solar-PV integration (5kW system covers 50% energy demand) and anammox processes to reduce aeration.
2. AI-Driven Optimization
Machine learning predicts fouling trends, dynamically adjusts aeration/cleaning cycles, cutting energy use by 15%.
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Conclusion
Flat-sheet MBR technology offers superior effluent quality and compact design, making it ideal for small-to-medium wastewater treatment (e.g., 10 tons/day systems). Its modularity, automation, and adaptability to diverse scenarios position it as a sustainable solution. Future integration with renewable energy and AI will further enhance its efficiency, driving the evolution of decentralized, smart water treatment infrastructure.
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