Lower Degree of Reactor Filling (10-15% of total Aeration volume)

Due to very high amount of available surface area for the colonization of active biomass on it, compared to conventional plastic MBBR carrier elements, Levapor carriers require only 10-15% reactor filling to achieve efficient and reliable process performance. The lower degree of filling allows for better movement of carriers as required for optimum mixing and mass transfer within the aerobic biological reactor.

Very high amount of active biomass (18-25 kg/m3) and higher process performance

Due to high amount of available surface area, fine pore structure, high adsorbing capacity and favourable ionic charges for better colonization and biofilm formation, Levapor carriers allow for retention of up to 18-25 kg of active biomass per m3 of carrier elements added to the reactor.

The ideal combination of properties provides better mass transfer, optimum biofilm thickness and a diverse range of bacterial community development enabling Levapor based reactors to deliver 50-400 % higher process performance compared to suspended growth conventional activated sludge reactor and plastic media based MBBRs for the same volumetric foot print.

The high amount of active biomass fraction retained within the reactor on Levapor carriers also facilitate to operate the reactors with relatively higher MCRT(Mean Cell Retention Time) / SRT (Sludge Retention Time) at lower Hydraulic Retention time.

Smaller foot Print and Compact plants

Due to higher performance achievable with Levapor carrier based bioreactors, the volumetric and organic loading rates observed with Levapor carriers are much higher compared to conventional technologies which reduces the Aerobic Reactor volume requirement resulting in smaller foot print of the plant.

Faster Wetting, Colonization and lower fluidization energy

Due to hydrophilic nature of Poly Ether based PU foams, the wetting of Levapor carriers takes significantly faster compared to conventional hydrophobic plastic material. Within 3-5 days complete wetting can be observed after adding carriers in the reactor filled with liquid. The shape and density of the carriers allow for smoother fluidization of the carriers within the reactor. With energy as low as 4-7 Nm3/m2.hr, the reactor bed with Levapor carriers can be fluidized efficiently.

Due to specific properties developed because of the combination of PE-PU foam and carbon impregnation along with fine pore structure, the initial colonization takes place very quickly and after seeding, the reactor starts delivering remarkable removal rate for organic removal within few days.

Higher Process stability against toxic shock loads

The presence of Activated carbon on Levapor carriers offers a remarkable process stability to Levapor based bioreactors against toxic shock loads compared to conventional activated sludge and plastic media based MBBR processes. The specific advantage of PACT system exploited helps reducing the toxicity of the toxic substances and thus allow smoother and higher process performance even with the presence of such toxic substance. This specific characteristic of Levapor carriers enables the biological treatment of toxic and inhibitory substance containing effluents at much higher removal rates and at better process economies.

Also the inner porosity of Levapor carriers offer added protection to the biofilms against such toxic shock loads resulting in higher security against such events making biological process with Levapor carriers much stable for effluents containing toxic substances.

Reduced, well settled sludge production and improved clarifier performance

The optimum combination of properties developed with Levapor carriers results in formation of highly efficient environmental conditions with respect to Biofilm Thickness, substrate/Diffusion Gradients, attachment/detachment of biomass, maintenance of biofilm thickness and higher activities within the Levapor based bioreactors. This combination of favourable conditions results in development of a diverse microbial community structure having better settling properties. Due to better settling properties, the performance of conventional clarifiers with Levapor carriers is dramatically improved with excellent solids separation achieved.

Benefits of Levapor Technology:

  • Smaller foot print and reduced CAPEX
  • Remarkable process stability against toxic shock loads
  • 50-400 % higher process performance compared to conventional technologies
  • Reduced process start up and commissioning periods
  • Lower Energy Consumption
  • Reduced Sludge Production
  • Improved clarifier performance
  • Better results under all operating conditions