Aerobic - FlooBed® - Nijhuis Saur Industries

Your challenges

Treating high organic loadings in varying process conditions to efficiently remove nutrients and organics in a wide variety of wastewater systems

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Reduction of organic pollution (COD/BOD):

Organic pollution originates from industrial, human, animal or agricultural activity. These pollutants are a major concern for both industrial and municipal wastewater management due to their environmental and health impacts.

Regulatory compliance

One of the most critical challenges clients faces are ensuring that their wastewater discharges meet strict environmental laws and regulations. Non-compliance can lead to fines, legal issues, reputational damage, or shutdowns. Permits often require monitoring, reporting, and audits, with some industries needing to meet additional sector-specific standards.

Adaptability to variable loads

In industrial and mixed-use municipal systems—the composition and volume of wastewater can change significantly over time. These fluctuations often involve variations in flow rate, organic load (BOD/COD), pH, temperature, and concentrations of nutrients or toxic substances. Such variability can challenge conventional treatment systems, which may lack the flexibility to adapt effectively, resulting in performance drops and potential violations of discharge regulations.

Low space requirement

Limitation in facilities with restricted floor space or where compact system integration is critical. FlooBed® offers possibilities to reuse existing basins to build FlooBed® systems, can also be adapted into basins with different shapes.

How does it work ?

FlooBed® MBBR is a highly efficient, patented compact biological treatment process. Our advanced biofilm carrier elements combined with optimized, energy efficient aeration and mixing in a continuous process control forms a strong basis to treat high organic loadings in varying process conditions to efficiently remove nutrients and organics to meet different discharge permit requirements.

The carriers build a floating bed into the water. The filling ratio of biofilm carriers can be adjusted according to load and environmental requirements. The floating bed is stirred by a unique FlooBed® aeration system for highly efficient oxygenation and mixing of biofilm media. In traditional fixed-film systems the excessive growth of sludge often causes clogging. The FlooBed®, -process minimizes this risk by optimizing carrier design and reactor conditions. The reactor volume is totally mixed and there is no “unused” space in the FlooBed® bioreactors. Biofilm carriers are kept inside the reactor with screens that are placed at the outlet and inlet of the reactor.
Depending on application, the effluent from FlooBed® MBBR process can be led to solids separation. Different technologies can be used for solids separation including dissolved air flotation (DAF), sedimentation or lamella clarifier. Clarified effluent can be then discharged or reused.
The FlooBed® process can have one or several stages which can be operated in series and parallel. An existing conventional process can be upgraded with FlooBed® MBBR to function as a modern FlooBed® BAS process.
The efficiency can be further increased by recycling separate parts of the sludge back to the MBBR in certain applications. With returning sludge, it is possible to improve the stability of the process and increase the biomass diversity and thus achieve an exceptionally stabile biological process with extremely high treatment efficiency.

Our positive impact

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Reduced Water Consumption

Possibility adjust the filling ratio according to flow and load to ensure optimized water consumption.

Reduced Energy Usage

FlooBed® MBBR Aeration system covers the entire bottom area – efficient use of capacity. The adjustable aeration mixing combined with enhanced air diffusers to optimize process and energy efficiency. >25% lower energy consumption compared to other aeration systems.

Reliable and Easy Operation

Capable of treating high organic loads in varying process conditions and resistant to toxic shocks, no blocking tendency and no backwashing needed.

Low Space Requirement

Compact build enables huge savings in site area, civil works, concrete works, piping, instrumentation and electrical cabling. The reactor volume needed for a FlooBed® system is considerably smaller compared to activated sludge plants (space requirement is typically 10-40% of conventional solutions). Also, there is the possibility to reuse existing basins or tanks with different shapes and materials e.g. concrete, stainless steel or FRP.