Integrated Bio-Reactor Biological Sewage Treatment System (IBR)

The Integrated Bio-Reactor (IBR) is a unique modification of the activated sludge process in which the clarifier is placed within the aeration tank. The above-ground design reduces system footprint and saves on costs associated with excavating and constructing traditional concrete basins.

Composed of aerobic, anoxic, and clarification zones, the IBR is designed to treat typical municipal wastewater. The operation and maintenance of the IBR is simple, as the system’s only moving mechanical parts are the aeration blowers, which drive air into the reactor.

  • Bolted-steel structure eliminates need for expensive concrete tanks
  • 30-foot high tank walls allow for increased oxygen transfer
  • Internal clarifier tank reduces system footprint
  • Reduced detention time delivers higher processing rate
  • Minimal moving parts means lower power requirement and reduced maintenance
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How the IBR Works

The Integrated Biological Reactor® has a vertical installation that results in a comparatively small footprint. The vertical installation also allows for an increase in the oxygen transfer rate to the wastewater. The wastewater is aerated using atmospheric air; this air is aspirated to the liquid by passing it through an air blower and a series of diffusers. This results in a simple and effective aerobic process.

The air is discharged through the bottom of the bioreactor. At this point the air is released flowing upward from roughly twice the standard depth of a normal Activated Sludge system. This, in turn, results in greater efficiency of Oxygen saturation into the wastewater.

The result of this retention time of air in the effluent, together with the perfect mixing of the extremely small micro bubbles of air with the liquid, creates the most effective and highest diffusion coefficient of oxygen in the water to date.

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The IBR's bolted tank structure reduces installation time in comparison to welded or concrete tanks
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Bolted tanks are built on a concrete slab to reduce steel requirement and deliver cost savings to our clients
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Coarse air diffusers placed at a depth of 9+ meters allow for high-efficiency air transfer and optimum microbial growth conditions
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An integrated clarifier reduces system footprint and saves on capital cost
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Sludge settles in the clarifier preparing treated effluent for discharge
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An optional sludge holding tank can be integrated to allow for sludge treatment flexibility
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IBR systems can be sized to treat millions of gallons of water per day
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The IBR is a cost effective solution for high-flow municipal applications

Integrated Bio-Reactor System Models

Model Flow (GPD) m3/day Population Equivalent Outer Tank Diameter (ft) Power Installed
(kW/hr)
IBR-100 100,000 378.5 1893 18 9
IBR-200 200,000 757 3785 25 18
IBR-300 300,000 1135.5 5678 31 26
IBR-400 400,000 1514 7570 36 35
IBR-500 500,000 1892.5 9463 40 44
IBR-600 600,000 2271 11355 44 53
IBR-700 700,000 2649.5 13248 48 62
IBR-800 800,000 3028 15140 51 70
IBR-900 900,000 3406.5 17033 54 79
IBR-1000 1,000,000 3785 18925 57 88

IBR Competitive Performance Analysis

Process Solids Retention Time (day) F/M (kg BOD/kg MLVSS day) Volumetric Load (kg BOD/m3/day) MLSS (mg/L) Total Hydraulic Retention Time (hr) Return Activated Sludge (% influent)
High Rate Aeration 0.5 - 2.0 1.5 - 2.0 1.2 - 2.4 200 - 1000 1.5 - 3 100 - 150
SBR - Sequencing Batch Reactor 10 - 30 0.04 - 0.1 0.1 - 0.3 2000 - 5000 15 - 40 n/a
Extended Aeration 20 - 40 0.04 - 0.1 0.1 - 0.3 2000 - 5000 20 - 30 50 - 150
Integrated Bio-Reactor 10 - 50 0.1 - 2.5 1.2 - 2.4 3000 - 6000 5 - 10 50 - 150

Sludge and Energy Reductions Realized

Significant sludge reduction achieved through use of IBR

Municipal wastewater treatment plant for 1M inhabitant city:

  • High rate sludge production: 55g BOD5 x 1M x 0.55 = 30.25 Tons/day
  • Extended aeration = 24.75 Tons/day
  • Integrated Bio-Reactor = 4.95 Tons/day
Sludge reduction per year: (30.25 – 4.95) x 365 = 9,234.5 Tons/year

IBR Comparitive Energy Consumption

Municipal wastewater treatment plant for 1M inhabitant city:

  • High rate aerobic = energy required 5,958 kWh
  • Extended aeration = 4,182 kWh
  • Integrated Bio-Reactor = 1,895 kWh

Energy reduction per year: (5,958 – 1,895) x 24 x 365 = 35,591 MW/year

Client Recommendations

The 2.65MGD IBR system built at Russky Island, Russia has been fully automated and operational since the end of 2012. Our client was so impressed with the project that he left us with his endorsement and testimonial.
View the letter
During his statement at a preparatory meeting for APEC 2012, former President of Russia, Dmitry Medvedev says that the new wastewater treatment facility alone was worth holding the summit at Russky Island.
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