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A SunCam online continuing education course
MBBR Wastewater Treatment Processes

by
Harlan H. Bengtson, PhD, P.E.

1. Introduction
The Moving Bed Biofilm Reactor (MBBR) wastewater treatment process is a relatively
recent addition in the wastewater treatment field. It was developed in Norway in the
1980s and is now in use in many countries throughout the world. It is an attached
growth process, but is similar to activated sludge in some ways also. It uses plastic
carriers to provide a surface on which biofilm grows. The plastic carriers are kept
suspended in the aeration tank by an aerator for an aerobic process or by mechanical
mixing for an anoxic or anaerobic process. The plastic carriers are kept in the system by
a sieve at the outlet of the tank. There is no need for sludge recycle in an MBBR
process and the required reactor size is typically significantly smaller than for an
activated sludge process treating the same wastewater flow, or for other common
attached growth processes like the trickling filter or RBC. The MBBR process can be
used for BOD removal, nitrification and/or denitrification. This course includes
background information about the MBBR process and a description of a commonly used
design approach, along with several worked examples illustrating the calculations.
A sample spreadsheet for making MBBR process design calculations is included with
this course. Coverage of spreadsheet use for MBBR process design calculations is
discussed in the course and illustrated with example calculations.
www.SunCam.com Copyright 2017 Harlan H. Bengtson Page 2 of 49

2. Learning Objectives
At the conclusion of this course, the student will
Know the differences between attached growth and suspended growth biological
wastewater treatment processes
Be familiar with the general configuration and components of an MBBR

wastewater treatment process
Be able to name the six MBBR process configurations discussed in this course
Be able to calculate the loading rate of a wastewater constituent to an MBBR

process (in lb/day and g/day) for specified wastewater flow rate and constituent
concentration
Be able to calculate the required carrier surface area for an MBBR wastewater
treatment process for specified SALR and loading rate
Be able to calculate the required MBBR tank volume for specified carrier surface
area, carrier specific surface area, and the carrier fill %
Be able to calculate the liquid volume in an MBBR tank for known tank volume,
carrier volume and carrier % void space
Be able to calculate the BOD, NH3-N, or NO3-N removal rate for known values of
the surface area removal rate (SARR) and design carrier surface area
Be able to calculate an estimated effluent BOD, NH3-N, or NO3-N concentration

based on known values of the appropriate loading rate, estimated removal rate,
and design wastewater flow rate

Be able to use the sample spreadsheet included with the course to make process
design calculations for a single stage BOD removal process in either U.S. units
or S.I. units.
Be able to use the sample spreadsheet included with the course to make process
design calculations for a single stage nitrification process in either U.S. units or
S.I. units.
Be able to make process design calculations for a post-Anoxic denitrification

MBBR process, including required tank sizes, estimated effluent concentrations,
alkalinity requirement and carbon source requirement.
Be able to make process design calculations for a pre-anoxic denitrification

MBBR process, including required tank sizes, estimated effluent concentrations,
and alkalinity requirements.
3. Topics Covered in this Course
I. General Information about the MBBR Wastewater Treatment Process
A. Initial Development of the Process

B. General Description of the Process
C. The MBBR Media Support Carrier System
D. MBBR Process Alternatives
II. MBBR Process Design Calculations BOD Removal and Nitrification
A. Overview of MBBR Process Design Calculations

B. Single Stage BOD Removal Process Design Calculations
C. Single Stage Tertiary Nitrification Design Calculations
D. Two-Stage BOD Removal Process Design Calculations
E. Two-Stage BOD Removal/Nitrification Design Calculations
III. MBBR Denitrification Processes

A. Introduction to MBBR Denitrification Processes

B. Post-Anoxic Denitrification Process Design Calculations
C. Pre-Anoxic Denitrification Process Design Calculations
IV. Summary
V. References
4. General Information about the MBBR Wastewater

Treatment Process
Initial Development of the Process
The MBBR process for wastewater treatment was invented and initially developed by
Professor Hallvard degaard in the late 1980s at the Norwegian University of Science
and Technology. Use of this wastewater treatment process has spread rapidly. Per
degaard, 2014 (Reference #1 at the end of this course), there were already more than
800 MBBR wastewater treatment plants in more than 50 countries at that time (2014),
with about half treating domestic wastewater and about half treating industrial
wastewater. At least part of the reason for the interest in the MBBR process is its small
footprint in comparison with other biological treatment processes. The tank volume
needed for a MBBR process is typically significantly less than that needed for either an
activated sludge process or a trickling filter designed to treat the same wastewater flow.
General Description of the Process
The MBBR process is an attached growth biological wastewater treatment process.

That is, the microorganisms that carry out the treatment are attached to a solid medium,
as in trickling filter or RBC systems. By contrast, in a suspended growth biological
wastewater treatment process, like the activated sludge process, the microorganisms
that carry out the treatment are kept suspended in the mixed liquor in the aeration tank.

In the conventional attached growth, biological treatment processes, like trickling filter or
RBC systems the microorganisms are attached to a medium that is fixed in place and
the wastewater being treated flows past the surfaces of the medium with their attached
biological growth. In contrast, an MBBR process utilizes small plastic carrier media
that are described in more detail in the next section. The MBBR treatment processes
typically take place in a tank similar to an activated sludge aeration tank. The carrier
media are kept suspended by a diffused air aeration system for an aerobic process or
by a mechanical mixing system for an anoxic or anaerobic process, as indicated in
figures 1 and 2 below. A sieve is typically used at the tank exit to keep the carrier
media in the tank.
Primary clarification is typically used ahead of the MBBR tank. Secondary clarification
is also typically used, but there is no recycle activated sludge sent back into the
process.
The MBBR Media Support Carrier System

MBBR processes use plastic media support carriers similar to those shown in Figure 3.
As shown in the figure, the carrier is typically designed to have a high surface area per
unit volume, so that there is a lot of surface area on which the microorganisms attach
and grow. Media support carriers like those shown in Figure 3 are available from
numerous vendors. Two properties of the carrier are needed for the process design
calculations to be described and discussed in this course. Those properties are the
specific surface area in m2/m3 and the void ratio. The specific surface area of MBBR
carriers is typically in the range from 350 to 1200 m2/m3 and the void ratio typically
ranges from 60% to 90%. Design values for these carrier properties should be obtained
from the carrier manufacturer or vendor.
MBBR Process Alternatives
The MBBR wastewater treatment process is quite flexible and can be used in several
different ways. There will be a description and discussion of the following six MBBR
process alternatives in this course:
1. Single stage BOD removal

2. Single stage tertiary Nitrification
3. Two-stage BOD removal
4. Two-stage BOD removal and Nitrification
5. Pre-Anoxic BOD removal/Nitrification/Denitrification

6. Post-Anoxic BOD removal/Nitrification/Denitrification
Flow diagrams for these six MBBR process alternatives are shown in the diagram
below:
Figure 4. MBBR Wastewater Treatment Process Alternatives
Each of the process alternatives shown in Figure 4 will be covered in more detail later in
the course.

5. MBBR Process Design Calculations for BOD Removal

and Nitrification
Overview of MBBR Process Design Calculations
The key empirical design parameter used to determine the required MBBR tank size is
the surface area loading rate (SALR) in g/m2/d. The g/d in the SALR units refers to the
g/d of the parameter being removed and the m2 in the SALR units refers to the surface
area of the carrier. Thus, for BOD removal the SALR would be g BOD/day entering the
MBBR tank per m2 of carrier surface area. For a nitrification reactor, the SALR would
be g NH3-N/day entering the MBBR tank per m2 of carrier surface area. Finally, for
denitrification design, the SALR would be g NO3-N/day per m2 of carrier surface area.
For any of these processes, a design value for SALR can be used together with design
values of wastewater flow rate and BOD, ammonia or nitrate concentration, to calculate
the required carrier surface area in the MBBR tank. The design carrier volume can then
be calculated using a known value for the carrier specific surface area (m2/m3). Finally,
a design value for the carrier fill % can be used to calculate the required tank volume.
Process design calculations for each of the process alternatives shown in Figure 4 will
be covered in the next several sections.
Single Stage BOD Removal Process Design Calculations
An MBBR single stage BOD removal process may be used as a free-standing

secondary treatment process or as a roughing treatment prior to another secondary
treatment process, in some cases to relieve overloading of an existing secondary
treatment process. In either case the key design parameter for sizing the MBBR tank is
the surface area loading rate (SALR), typically with units of g/m2/day, that is g/day of
BOD coming into the MBBR tank per m2 of carrier surface area. Using design values
for wastewater flow rate and BOD concentration entering the MBBR tank, the loading
rate in g BOD/day can be calculated. Then dividing BOD loading rate in g/day by the
SALR in g/m2/day gives the required carrier surface area in m2. The carrier fill %,
carrier specific surface area, and carrier % void space can then be used to calculate the

required carrier volume, tank volume and the volume of liquid in the reactor. A typical
flow diagram for a single stage MBBR BOD removal process is shown in Figure 5
below.
Figure 5. Single Stage MBBR Process for BOD/COD Removal
The equations for making those calculations are as follows:
1. BOD loading rate = Q*So*8.34*453.59
where: Q is the wastewater flow rate into the MBBR reactor in MGD
So is the BOD concentration in that influent flow in mg/L
8.34 is the conversion factor from mg/L to lb/MG
453.59 is the conversion factor from lb to g
The calculated BOD loading rate will be in g/day.
2. required carrier surface area = BOD Loading Rate/SALR
where: BOD Loading Rate is in g/day

SALR is the design surface area loading rate in g/m2/day

The calculated required carrier surface area will be in m2.
3. required carrier volume

= required carrier surface area/carrier specific surface area
where: required carrier surface Area is in m2

carrier specific surface Area is in m2/m3
The calculated required carrier volume will be in m3.
4. required tank volume = required carrier volume/carrier fill %
where: required tank volume will be in the same units as required carrier volume.
Use of an Excel Spreadsheet
The type of calculations just discussed can be done conveniently using an Excel
spreadsheet. The screenshot in Figure 6 below shows a screenshot of worksheet 2 of
the course spreadsheet set up to make the calculations just described for Example #1.
The worksheet shows user input values of the given information entered in the blue
cells. The values in the yellow cells are calculated by the spreadsheet using the
equations presented and discussed above. The values calculated by the spreadsheet
for the following parameters are the same as those shown in the solution to Example
#1 above: i) the BOD loading in g/day, ii) the required tank volume, iii) the liquid
volume in the tank, iv) the hydraulic retention time at design average flow, and v) the
hydraulic retention time at peak hourly flow.
You may have noticed that there are a few additional calculations in the worksheet
screenshot. If the user selected tank shape is rectangular, the worksheet calculates
the tank length and width for the calculated required tank volume. If the user selected
tank shape is cylindrical, the worksheet will calculate the tank diameter. These
calculations simply use the formulas for the volume of a rectangular tank (V = L*W*H) or
for the volume of a cylindrical tank (V = D2H/4), with user entered values for L:W ratio
being used for rectangular tank calculations and the user entered value for the liquid
depth in the tank, H, being used by both. The worksheet also calculates an estimated
effluent BOD concentration, which is discussed in the next section (after Example #2,
which illustrates a solution with S.I. units).


Figure 6. Screenshot Single Stage BOD Removal Calculations U.S. units
Example #2: (working with S.I. units) Repeat Example #1 if the wastewater flow is
specified as 757 m3/d instead of 0.2 MGD. The rest of the given information remains
the same. The wastewater flow containing 180 mg/L BOD is to be treated in an MBBR
reactor.
a) What is the BOD loading rate to the reactor in g/day?

b) What would be a suitable design SALR to use for a target removal of 90-95% ?
c) If the MBBR carrier has a specific surface area of 500 m2/m3 and design carrier
fill % of 40%, what would be the required volume of carrier and required MBBR
tank volume?
d) If the design carrier % void space is 60%, what would be the volume of liquid in
the MBBR reactor.
e) If the design peak hour factor is 4, calculate the average hydraulic retention time
at design average wastewater flow and at design peak hourly wastewater flow.
Solution:
a) The BOD loading rate will be (757 m3/d)(180 g/m3) = 136,260 g BOD/day
b) From Table 1 above, a suitable design SALR value for BOD removal with a
target BOD removal of 9095% would be 7.5 g/m2/day
c) Required carrier surface area = (136,260 g/day)/(7.5 g/m2/day) = 18,168 m2.
d) The volume of liquid in the reactor can be calculated as:

tank volume [carrier volume( 1 void %)], Thus the volume of liquid is: 90.8
[36.34(1 0.60)] = 76.3 m3.
e) The HRT at design ave ww flow can be calculated as:

HRTdes ave = reactor liquid volume/[Q/(24*60)]
= 76.3/[757/(24*60)] = 145 min
HRTpeak hr = HRTdes ave/peak hour factor = 145/4 = 36 min

The Excel spreadsheet screenshot on the next page (from worksheet 3 in the course
spreadsheet) shows the spreadsheet solution to Example #2. There are slight
differences from the solution with U.S. units due to rounding of the design flow
conversion from MGD to m3/s.

Figure 7. Screenshot Single Stage BOD Removal Calculations S.I. units

Estimation of Effluent Concentration
Use of an estimated surface area removal rate (SARR) allows calculation of the
estimated effluent concentration of the parameter being removed. That is, for BOD
removal, the estimated effluent BOD concentration can be calculated. For nitrification,
the estimated effluent ammonia nitrogen concentration can be calculated and for
denitrification, the estimated effluent nitrate nitrogen concentration can be calculated.
Based on graphs and tables provided in several of the references at the end of this
course, the SARR/SALR ratio for all the different types of MBBR treatment being
covered in this course ranges from about 0.8 to nearly 1.0 over the range of SALR
values typically used. The SARR/SALR ratio is nearly one at very low SALR values and
decreases as the SALR value increases.
The upper right portion of the screenshot on the previous two pages illustrates an
approach for estimating a value for the SARR/SALR ratio for a specified design value of
SALR. In the four blue cells at the upper right, two sets of values for SARR/SALR and
SALR are entered. In this case, they are based on the typical values of % BOD removal
vs SALR in Table 1 above. In the yellow cells below those entries, the slope and
intercept of a SARR/SALR vs SALR straight line are calculated using the Excel SLOPE
and INTERCEPT functions. Then the SARR/SALR ratio is calculated for the specified
design value of SALR.
Note that the ratio SARR/SALR is equal to the % BOD removal expressed as a fraction.
This can be shown as follows:
BOD removal rate in g/day = (SARR in g/m2/d)(Carrier Surf. Area in m2)
BOD rate into plant in g/day = (SALR in g/m2/d)(Carrier Surf. Area in m2)
% BOD removal = (BOD removal rate/BOD rate into plant)*100%
= (100%)(SARR* Carrier Surf Area)/(SALR*Carrier Surf Area)
= (SARR/SALR)100%

Note that the value of 0.925 for the SARR/SALR ratio at SALR = 7.5 g/m2/d was
obtained from Table 1 above as the midpoint of the 90-95% estimated % BOD removal
for SALR = 7.5 g/m2/d. Similarly, the value of 0.875 for the SARR/SALR ratio at SALR
= 15 g/m2/d was obtained from Table 1 above as the midpoint of the 85-90% estimated
% BOD removal for SALR = 15 g/m2/d.
At the bottom of the screenshot worksheet, the estimated value of the surface area
removal rate (SARR) is calculated. It is used to calculate an estimated BOD removal
rate in g BOD/day and lb BOD/day. Then an estimate of the effluent BOD concentration
is calculated. The equations for these calculations are as follows:
1. estimated SARR = (calculated SARR/SALR)(design value of SALR)
2. estimated BOD removal rate = (estimated SARR)(carrier surface area)
3. estimated effluent BOD conc.

= [(BOD loading rate - estimated BOD removal rate)/Qo]/8.34
The calculations are exactly the same for S.I. units except that the 8.34 conversion
factor isnt needed in the last calculation.
Example #3: Calculate the estimated effluent BOD concentration for the wastewater
flow described in Example #1 being treated in the MBBR reactor sized in Example #1.
Solution: The solution is included in the Figure 6 and Figure 7 spreadsheet

screenshots that were used for the solutions to Example #1 and Example #2 above.
The pair of points for SARR/SALR vs SALR that were discussed above and are shown
on the Figure 6 and Figure 7 screenshots lead to the following values for the slope and
intercept for the SARR/SALR vs SALR line: Slope = -0.007, Intercept = 0.975.
Thus, the estimated SARR/SALR ratio for the given SALR value of 7.5 g/m2/d would be
calculated as: SARR/SALR = - (0.007)(7.5) + 0.975 = 0.925
The SARR value can be calculated as:
SARR = (SARR/SALR)(SALR) = (0.925)(7.5) = 6.94 g/m2/d

Then, the estimated BOD removal rate can be calculated as:
est BOD removal rate = (est SARR)(carrier surface area)
= (6.94 g/m2/d)(18,158.1 m2) = 125,972 g/d = 125,772/453.59 lb/day
est BOD removal rate = 277.7 lb/day (or 126,041 g/day)
The estimated effluent BOD concentration can then be calculated from the equation:
est effluent BOD conc. = [(BOD loading rate - est BOD removal rate)/Qo]/8.34
Substituting calculated and given values:
Est. effluent BOD conc. = [(300.2 277.7)/0.2]/8.34 = 14 mg/L
Note that this 14 mg/L value for the estimated effluent BOD concentration is shown
near the bottom of the Figure 6 and Figure 7 spreadsheet screenshots.
6. Single Stage Nitrification Process Design Calculations

A single stage MBBR nitrification process would typically be used as a tertiary treatment
process following some type of secondary treatment that reduced the BOD to a suitable
level. A typical flow diagram for a single stage MBBR process for nitrification is shown
in Figure 8 below. Note that alkalinity is used in the nitrification process, so alkalinity
addition is typically required. As shown on the diagram, the influent BOD level should
be low enough so that the BOD load to the nitrification process is less than 0.5
g/m2/day. Higher BOD loading to an MBBR nitrification reactor results in too many BOD
removing microorganisms and not enough nitrification microorganisms.

Figure 8. Single Stage MBBR Process for Nitrification
Table 2 below shows typical design values for the SALR (surface area loading rate) for
nitrification in an MBBR reactor. The source for the values in this table is the Odegaard
reference #2 below.
Table 2. Typical Design SALR Values for Nitrification
The process design calculations for this MBBR process are essentially the same as
those described above for a single stage BOD removal MBBR process. The graph
shown in Figure 9 (prepared using values from a similar graph in Rusten and

Paulsruds presentation in Ref #4 below) will be used to obtain values for SARR/SALR
vs SALR for nitrification.
Figure 9. SARR/SALR vs SALR for Nitrification
The process design calculations for single stage nitrification are illustrated in the next
example.
Example #4: A design secondary effluent flow of 0.2 MGD has the following
characteristics: 15 mg/L BOD, 35 mg/L TKN, and alkalinity of 140 mg/L as CaCO3.
This flow is to be treated in a single stage nitrification MBBR reactor. The design SALR
is to be 1 g NH3-N/m2/d.
a) What is the NH3-N loading rate to the reactor in g/day?

b) If the MBBR carrier has a specific surface area of 500 m2/m3 and design carrier
fill % of 40%, what would be the required volume of carrier and required MBBR
tank volume?
c) Calculate the BOD surface area loading rate (SALR) to ensure that it is less than
0.5 g BOD/m2/day.
d) If the design carrier % void space is 60%, what would be the volume of liquid in
the MBBR reactor.
e) If the design peak hour factor is 4, calculate the average hydraulic retention time
at design average wastewater flow and at design peak hourly wastewater flow.

f) The estimated effluent NH3-N concentration.

g) The alkalinity requirement in lb/day as CaCO3 and in lb/day NaHCO3.
Solution:
The solution, as calculated with the course spreadsheet, is shown in the screenshot in
Figure 10 below. A summary of the calculations is given here:
a) The Nitrate loading rate will be (0.2 MGD)(35 mg/L)(8.34 lb/MG/mg/L) = 58.4
lb/day = (58.4 lb/day)*(453.59 g/lb) = 26,481 g BOD/day
b) Required carrier surface area = (26,481 g/day)/(1 g/m2/day) = 26,481 m2.
Required carrier volume = 26,481 m2/500 m2/m3. = 52.96 m3 = (52.96

m3)(3.28083 ft3/m3) = 1870 ft3. (52.99 m3)
For 40% carrier fill: Required tank volume = 1870 ft3/0.40 = 4676 ft3.
(132.5 m3)
c) The BOD SALR will be (0.2 MGD)(15 mg/L)(8.34 lb/MG/mg/L)/(26481 m2) = 0.43
g/m2/day (Note that this is less than 0.5 g/m2/day as required.)
d) The volume of liquid in the reactor can be calculated as:

tank volume [carrier volume( 1 void %)], Thus the volume of liquid is: 4686
[1870(1 0.60)] = 3928 ft3. (111.3 m3)
e) The HRT at design ave ww flow can be calculated as:

HRTdes ave = reactor liquid volume*7.48/[Q*106/(24*60)] =
3928*7.48/[0.2*106/(24*60)] = 212 min
f) Calculation of the estimated effluent NH3-N concentration as shown above for the
single stage BOD removal process gives a value of 4.6 mg/L.

g) Calculation of the alkalinity requirement is shown in the Figure 11 spreadsheet

screenshot below. Using the equivalent weight of CaCO3 as 50, the equivalent
weight of NaHCO3 as 84, the alkalinity use for nitrification as 7.14 g CaCO3/g
NH3-N and the target effluent alkalinity as 80 mg/L as CaCO3, give the calculated
alkalinity requirement as 157.2 mg/L as CaCO3. The rate of alkalinity addition
needed can then be calculated as: (0.2 MGD)(157.2 mg/L)*8.34 = 262.2 lb/day
as CaCO3. (119 kg/day as CaCO3). Multiplying this by the ratio of the
equivalent weight of NaHCO3 to the equivalent weight of CaCO3 gives the daily
NaHCO3 requirement as 440.5 lb/day NaHCO3. (199.9 kg/d as NaHCO3).
The S.I. version of the spreadsheet can be used with the 0.2 MGD wastewater flow rate
specified as 757 m3/d. All of the other inputs remain as given above. The answers in
S.I. units (if different than the U.S. solution) are shown in parentheses at the end of
each part of the solution above.

Fig. 10. Screenshot of MBBR Process Design Calculations Single Stage Nitrification

Figure 11. Screenshot of MBBR Process Design Calculations Alkalinity Requirements
7. Two-Stage BOD Removal Process Design Calculations
A two-stage MBBR BOD removal process may be used instead of a single stage
process. In this case, a high SALR roughing treatment will typically be used for the
first stage and a lower SALR will typically be used for the second stage. This will result
in less total tank volume needed for a two-stage process than for a single stage
process. Also, a two-stage MBBR process can typically achieve a lower effluent BOD
concentration than a single stage MBBR process. A typical flow diagram for a two-
stage MBBR process for BOD removal is shown in Figure 12 below. Note that an
intermediate clarifier is not typically used between stages.

Figure 12. Two-Stage MBBR Process for BOD/COD Removal
The process design calculations for each stage of a two-stage MBBR process are
essentially the same as shown for the single stage process above in section 5. These
calculations are illustrated in Example #5.
Example #5: A design wastewater flow of 0.2 MGD (757 m3/d) containing 180 mg/L
BOD (in the primary effluent) is to be treated for BOD removal in a two stage MBBR
reactor. The design SALR for the first stage is to be 25 g/m2/d and the design SALR for
the second stage is to be 7.5 g/m2/d.
a) For the first stage calculate each of the following:

i) The BOD loading
ii) The required carrier volume for a carrier with specific surface area of 600 m2/m3
iii) The required MBBR tank volume for a design carrier fill % of 40%
iv) The volume of liquid in the MBBR reactor for design carrier % void space of 60%.
v) The average hydraulic retention time at design average wastewater flow and at
design peak hourly flow if the design peak hour factor is 4.
vi) The estimated effluent BOD concentration from the first stage.
b) Calculate the same parameters for the second stage.

Solution: The solution as calculated with an Excel spreadsheet is shown in the

spreadsheet screenshot in Figure 13 and Figure 14. Figure 13, which is the top part of
the spreadsheet, shows primarily the user input values. It also includes the calculation
of the slope and intercept for the SARR/SALR vs SALR equation and the calculation of
the estimated SARR for each stage. These calculations and the resulting SARR/SALR
values are the same as those discussed above for the single-stage BOD removal
MBBR process. The resulting values for SARR/SALR are 0.775 for the first stage with
SALR = 25, and 0.925 for the second stage with SALR = 7.5.
each part of the solution below
Figure 14 is the bottom part of the spreadsheet and shows the calculated values as
follows.
a) For the first stage:
i) The BOD loading rate will be (0.2 MGD)(180 mg/L)(8.34 lb/MG/mg/L) = 300.2
ii) Required carrier surface area = (136,186 g/day)/(25 g/m2/day) = 5447.4 m2.
Required carrier volume = 5447.4 m2/600 m2/m3. = 10.895 m3 = (10.895

m3)(3.28083 ft3/m3) = 384.7 ft3. (10.895 m3)
iii) For 40% carrier fill: Required tank volume = 384.7 ft3/0.40 = 961.9 ft3.
iv) The volume of liquid in the reactor can be calculated as:

[384.7(1 0.60)] = 808 ft3. (22.88 m3)
v) The HRT at design ave ww flow can be calculated as:

808*7.48/[0.2*106/(24*60)] = 44 min

Calculation of the estimated effluent BOD concentration from the first stage as shown
above for the single stage process gives a value of 41 mg/L.

Figure 13. Screenshot of MBBR Process Design Calculations Two-Stage BOD Removal Part 1

Figure 14. Screenshot of MBBR Process Design Calculations Two-Stage BOD Removal Part 2

b) For the second stage:
i) The BOD loading rate will be (0.2 MGD)(41 mg/L)(8.34 lb/MG/mg/L) = 67.6
ii) Required carrier surface area = (30642 g/day)/(7.5 g/m2/day) = 4085.6 m2.
Required carrier volume = 4085.6 m2/600 m2/m3. = 8.171 m3 = (8.171

m3)(3.28083 ft3/m3) = 288.6 ft3. (8.171 m3)
iii) For 40% carrier fill: Required tank volume = 288.55 ft3/0.40 = 721.4 ft3.
(20.43 m3)

[288.6(1 0.60)] = 606 ft3. (17.1 m3)

606*7.48/[0.2*106/(24*60)] = 33 min
Calculation of the estimated effluent BOD concentration from the second stage as
shown above for the single stage process gives a value of 3.0 mg/L.
Example #6: Compare the MBBR tank volume, carrier surface area, and estimated
effluent BOD concentration for the single stage BOD removal process in Example #1
and the same WW flow and BOD with a two-stage BOD removal process as calculated
in Example #5.
Solution: The results are summarized below:
Single Stage Process Two Stage Process

MBBR Volume: 3206 ft3 1683 ft3
Carrier Surf. Area: 18158 m2 9533 m2

Est. Effl. BOD: 14 mg/L 3 mg/L
Note that the two-stage process requires only about half of the tank volume and half of
the carrier quantity in comparison with the single stage process, while achieving a
significantly lower estimated effluent BOD.
8. Two-Stage BOD Removal and Nitrification Process

Design Calculations
A two stage MBBR process may also be used to achieve both BOD removal and
nitrification. Nitrification with an MBBR process requires a rather low BOD
concentration. Thus the first stage for this process is used for BOD removal and the
second stage is used for nitrification. A typical flow diagram for a two stage MBBR
process for BOD removal and nitrification is shown in Figure 15 below.
Figure 15. Two-Stage MBBR Process for BOD Removal and Nitrification
Table 3 shows typical design values for the SALR (surface area loading rate) for the
BOD removal stage and for the nitrification stage. The source for the values in this
table is the Odegaard reference #2 below.

Table 3. Typical Design SALR Values for Nitrification
The process design calculations for the two-stage BOD Removal/Nitrification process
would be essentially the same as those just discussed for the two-stage BOD removal
process, with the second stage calculations being like those for the single stage
nitrification process.
9. Introduction to MBBR Denitrification Processes
Denitrification Background: In order to carry out denitrification of a wastewater flow

(removal of the nitrogen from the wastewater), it is necessary to first nitrify the
wastewater, that is, convert the ammonia nitrogen typically present in the influent
wastewater to nitrate. As previously noted, nitrification will only take place at a
reasonable rate if the BOD level is quite low. Thus, an MBBR denitrification process will
need a reactor for BOD removal, one for nitrification, and one for denitrification. The
nitrification reactor will always follow the BOD removal reactor, because of the need for
a low BOD level in the nitrification reactor. The denitrification reactor may be either
before the BOD removal reactor (called pre-anoxic denitrification) or after the
nitrification reactor (called post-anoxic denitrification). Flow diagrams for these two
denitrification options are shown in Figure 16 below.

Figure 16. MBBR Denitrification Process Alternatives
A bit more information about the denitrification reactions will be useful for further
discussion of these two denitrification options. The denitrification reactions, which
convert nitrate ion to nitrogen gas, and hence remove it from the wastewater flow, will
take place only in the absence of oxygen, that is, in an anoxic reactor. Also, the
denitrification reactions require a carbon source. With these factors in mind the
functioning of the pre-anoxic denitrification process and of the post-anoxic denitrification
process can be described as follows.
In a pre-anoxic denitrification process, the BOD in the primary effluent wastewater is

used as the carbon source for denitrification. In this process, however the primary
effluent entering the pre-anoxic reactor still has ammonia nitrogen present rather than
the nitrate nitrogen needed for denitrification. A recycle flow of effluent from the
nitrification reactor is used to send nitrate nitrogen to the denitrification reactor.
In a post-anoxic denitrification process, the influent to the denitrification reactor comes

from the nitrification reactor, so the ammonia nitrogen present in the wastewater influent

has been converted to nitrate as required for denitrification. The BOD has also been
removed prior to the post anoxic denitrification reactor, however, so an external carbon
source is required for the denitrification reactions. Methanol is a commonly used carbon
source.
Choosing between Pre-Anoxic and Post-Anoxic Denitrification: The pre-anoxic

denitrification process has the advantage of not requiring an external carbon source and
it reduces the BOD load to the BOD removal part of the process because BOD is used
in the denitrification reactions. However, the pre-anoxic process requires an influent
C/N ratio greater than 4, where C/N is taken to be BOD/TKN, and the post-anoxic
process can achieve a more complete nitrogen removal.
From the Odegaard references (#1 and #2 below) suitable criteria for determining
whether to use pre- or post-anoxic denitrification are as follows:
1. Pre-anoxic denitrification is suitable if C/N > 4

and target % Removal of N < 75%
2. Post-anoxic denitrification should be used if C/N < 4

or target % Removal of N > 75%
10. Post-Anoxic Denitrification Process Design

Calculations
Process design of a post-anoxic denitrification MBBR system, requires sizing an MBBR

tank for BOD removal, one for nitrification and one for denitrification. For each of these
three reactors the calculations for sizing the reactor are as discussed and illustrated
with examples above. A typical flow diagram for a post-anoxic denitrification MBBR
process is shown in Figure 17 below.

Figure 17. Flow Diagram for Post-Anoxic Denitrification
Example #7: A design wastewater flow of 0.2 MGD containing 180 mg/L BOD, 35 mg/L
TKN, and 140 mg/L alkalinity as CaCO3 (in the primary effluent) is to be treated in a
post-anoxic denitrification MBBR process. Carry out the process design for the
denitrification stage as described below, using a design SALR of 2 g NO3-N/m2/d.
For the third (Denitrification) stage calculate each of the following:
i) The nitrate loading

vi) The estimated effluent NO3-N concentration from the denitrification stage.
vii) The alkalinity requirement in lb/day as CaCO3 and in lb/day NaHCO3, for target
effluent alkalinity of 80 mg/L as CaCO3.
viii)The methanol requirement in lb/day for methanol use as the carbon source.
Solution: The nitrate loading to the anoxic reactor will be calculated using (primary
clarifier TKN conc. effluent nitrate conc. from nitrification stage) as the nitrate
concentration coming into the post anoxic reactor. Thus, the BOD removal reactor and
Nitrification reactor must be designed before the post-anoxic denitrification reactor. The

results for those two reactors will be presented and briefly discussed first. Then the
calculations for the anoxic stage will be presented.
The calculations for the BOD removal stage would be carried out as described in
Examples #1 and #3, using 6.0 g BOD/m2/d as the design SALR based on Table 3,
rather than the 7.5 g BOD/m2/d used in Examples #1 & #3. The BOD Daily Loading is
the same as that calculated in Example #1, 136,186 g/day or 300.2 lb/day. The
required tank size is a bit larger because of the lower design SALR used in this case
and the calculated effluent BOD concentration is 12 mg/L rather than the 14 mg/L
calculated in Example #1 (with the 7.5 value for SALR). The results for the BOD stage
calculations are shown in the Figure 18 spreadsheet screenshot below.
The calculations for the Nitrate removal stage would be carried out exactly the same as
described in Example #4 for a single stage nitrate removal process with the same
wastewater flow rate, influent TKN, and design SALR (1 g NH3-N/m2/d). The results are
shown in the Figure 10 spreadsheet screenshot, including the calculated effluent NH3-N
concentration of 4.6 mg/L from this stage.
The calculations for the post-anoxic denitrification stage are as follows. The S.I. version
of the spreadsheet can be used with the 0.2 MGD wastewater flow rate specified as 757
m3/d. All of the other inputs remain as given above. The answers in S.I. units (if
different than the U.S. solution) are shown in parentheses at the end of each part of the
solution below
i) The NO3-N loading rate will be (0.2 MGD)(35 - 4.6 mg/L)(8.34 lb/MG/mg/L) =
50.7 lb/day = (50.8 lb/day)*(453.59 g/lb) = 23,016 g NO3-N/day
(Note that 35 mg/L is the primary effluent TKN concentration and 4.6 mg/L is
the estimated effluent NH3-H concentration.}
ii) Required carrier surface area = (23016 g/day)/(2 g/m2/day) = 11508 m2.
Required carrier volume = 11508 m2/500 m2/m3. = 23.02 m3 =

(23.02 m3)(3.28083 ft3/m3) = 812.9 ft3. (23.02 m3)

Figure 18. Screenshot Post-Anoxic Denitrification Calculations BOD Removal Stage

iii) For 40% carrier fill: Required tank volume = 812.9 ft3/0.40 = 2032 ft3.
(57.55 m3)

[812.9(1 0.60)] = 1707 ft3. (48.34 m3)

1707*7.48/[0.2*106/(24*60)] = 92 min
vi) Calculation of the estimated effluent NO3-N concentration from the second stage,
is done as discussed in previous examples and gives a value of 4.6 mg/L.
These results are shown in the Figure 19 spreadsheet screenshot below
vii) Calculation of the alkalinity requirement is shown in the Figure 20

spreadsheet screenshot below. Note that alkalinity is produced in the
denitrification reactions, so less alkalinity addition will be needed with
denitrification present. Using the equivalent weight of CaCO3 as 50, the
equivalent weight of NaHCO3 as 84, the alkalinity use for nitrification as 7.14
g CaCO3/g NH3-N, the alkalinity produced by denitrification as 3.56 g
CaCO3/g NO3-H, and the target effluent alkalinity as 80 mg/L as CaCO3, give
the calculated alkalinity requirement as 48.5 mg/L as CaCO3. The rate of
alkalinity addition needed can then be calculated as: (0.2 MGD)(48.5
mg/L)*8.34 = 81.0 lb/day as CaCO3. (36.7 kg/day as CaCO3).
Multiplying this by the ratio of the equivalent weight of NaHCO3 to the
equivalent weight of CaCO3 gives the daily NaHCO3 requirement as 136.0
lb/day NaHCO3. (61.7 kg/day as NaHCO3)
viii) Calculation of the methanol requirement in lb/day is shown at the bottom of

the Figure 20 screenshot. As shown, the calculations use the constants, 4.6
lb COD/lb NO3-N removed and 1.5 lb COD/lb Methanol. The required

methanol dosage is then calculated as: 4.6/1.5

= 3.1 lb methanol /lb NO3-N removed. The methanol requirement in lb/day is
then equal to 3.1 times the previously calculated NO3-N removal rate of 43.1
lb/day, or 132.3 lb/day. (60.0 kg/day)
Figure 19. Post-Anoxic Denitrification Calculations Anoxic Stage Part 1

Figure 20. Post-Anoxic Denitrification Calculations Anoxic Stage Part 2

11. Pre-Anoxic Denitrification Process Design Calculations
The process design calculations for pre-anoxic denitrification, are similar to those just
discussed for a post-anoxic denitrification process. The graph shown in Figure 21
(prepared using values from a similar graph in Rusten and Paulsruds presentation in
Ref #4 below) will be used to obtain values for SARR/SALR vs SALR for the pre-anoxic
denitrification stage.
Figure 21. SARR/SALR vs SALR for Pre-Anoxic Denitrification
A typical flow diagram for a pre-anoxic denitrification MBBR process is shown in

Figure 22 below. As discussed previously for a post-anoxic denitrification MBBR
system, process design of a pre-anoxic denitrification MBBR system also requires sizing
an MBBR tank for BOD removal, one for nitrification and one for denitrification. Process
design for the nitrification stage is essentially the same as just discussed for the post-
anoxic denitrification process.

Figure 22. MBBR Flow Diagram for Pre-Anoxic Denitrification
Process Design results for the BOD removal stage will be a bit different from those for
the BOD removal stage in the post-anoxic process, because some of the incoming BOD
will be used as the carbon source in the denitrification reactions in the pre-anoxic tank.
For the pre-anoxic process, the BOD loading rate (in lb/day) should be calculated as:
BOD Daily Loading = (Qo*So*8.34) - (0.67*(20/7)*NO3-N removal rate)
The second term is the estimated BOD removal rate in the anoxic reactor through its
use in the denitrification reactions. This gives a lower BOD loading rate than that for the
post-anoxic process with the same primary clarifier effluent coming in. Hence the
required tank size for BOD removal will be smaller for the pre-anoxic process.
The main difference from the post-anoxic denitrification process design calculations is
for the denitrification stage, which will be discussed and illustrated with Example #8
calculations below.
Example #8: Carry out the process design as described below for the denitrification
stage of a pre-anoxic denitrification process with the wastewater flow and
concentrations given in Examples #1, #2, and #3. [0.2 MGD containing 180 mg/L BOD
and 35 mg/L TKN (in the primary effluent)]. Consider that the primary effluent alkalinity
is 140 mg/L as CaCO3 and the design SALR for the denitrification stage is to be 0.9 g
NO3-N/m2/d.

For the first stage (Denitrification) calculate each of the following:
i) The nitrate loading

vi) The required NO3-N recycle rate in order to achieve a target NO3-N
concentration of 9 mg/L.
vii) The alkalinity requirement in lb/day as CaCO3 and in lb/day NaHCO3, for target
effluent alkalinity of 80 mg/L as CaCO3.
Solution - The solution is shown in Figure 23, Figure 24, and Figure 25, which are
screenshots of different parts of an Excel worksheet used to carry out the calculations
for this example. Figure 23 is from the top part of the worksheet and shows the user
inputs and the calculation of the estimated SARR/SALR ratio for the denitrification
stage. Note also that a user input value is needed for the estimated NO3-N recycle
ratio. This initial estimated value is used in an iterative calculation to determine the
required NO3-N recycle ratio in order to achieve the target effluent NO3-N concentration.
each part of the solution below
Figure 24 is from the middle of the worksheet and shows the answers for parts i)
through vi). The calculations and results are as follows:
i) Most of the nitrate loading to the pre-anoxic denitrification tank is typically in the
NO3-N recycle flow rather than in the primary effluent flow entering the tank.
The NO3-N loading rate will be (0.2 MGD)(Prim Effl NO3-N)(8.34 lb/MG/mg/L)
+ (0.2 MGD)(Recycle Ratio)(Target Effl NO3-N)(8.34) = 38.6 lb/day = (38.6
lb/day)*(453.59 g/lb) = 17,489 g NO3-N/day
ii) Required carrier surface area = (17489 g/day)/(0.9 g/m2/day) = 19433 m2.

Required carrier volume = 19433 m2/500 m2/m3. = 38.865 m3 =

(38.865 m3)(3.28083 ft3/m3) = 1372 ft3. (38.865 m3)
iii) For 40% carrier fill: Required tank volume = 1372 ft3/0.40 = 3431 ft3.
(97.16 m3)

[1372(1 0.60)] = 2882 ft3. (81.61 m3)

1707*7.48/[0.2*106/(24*60)] = 155 min
.
vi) The required NO3-N recycle ratio is calculated with the iterative process
described in blue in the middle of Figure 24. For this iterative process, the
NO3-N removal rate is calculated two different ways, one using the estimated
SARR and the carrier surface area and the other using the wastewater flow
rate times the influent TKN concentration minus the sum of the effluent
nitrate and ammonia nitrogen. Excels Goal Seek process is then used to
set the difference between the two different calculations equal to zero by
changing the estimated value of the NO3-N recycle ratio. This process
results in the required NO3-N recycle ratio calculated to be 2.57.
ix) Calculation of the alkalinity requirement is shown in the Figure 25

spreadsheet screenshot. Using the equivalent weight of CaCO3 as 50, the
equivalent weight of NaHCO3 as 84, the alkalinity use for nitrification as 7.14
g CaCO3/g NH3-N, the alkalinity produced by denitrification as 3.56 g
CaCO3/g NO3-H, and the target effluent alkalinity as 80 mg/L as CaCO3, give
the calculated alkalinity requirement as 64.4 mg/L as CaCO3. The rate of
alkalinity addition needed can then be calculated as: (0.2 MGD)(64.4
mg/L)*8.34 = 107.4 lb/day as CaCO3. (48.7 kg/day as CaCO3)
Multiplying this by the ratio of the equivalent weight of NaHCO3 to the

equivalent weight of CaCO3 gives the daily NaHCO3 requirement as 180.4

lb/day NaHCO3. (81.8 kg/day as NaHCO3)

Figure 23. Screenshot Pre-Anoxic Denitrification Design Calculations Part 1


12. Summary
The MBBR (moving bed biofilm reactor) process is an attached growth process that
uses plastic carriers to provide a surface on which biofilm grows. The plastic carriers
are kept suspended in the aeration tank by an aerator for an aerobic process or by
mechanical mixing for an anoxic or anaerobic process. The plastic carriers are kept in
the system by a sieve at the outlet of the tank. The MBBR process doesnt require
sludge recycle, because the biomass remains in the system attached to the plastic
carrier. The required reactor size for an MBBR process is typically significantly smaller
than for an activated sludge process treating the same wastewater flow, or for other
common attached growth processes like the RBC or trickling filter. It can be used for
BOD removal, biological nitrification, biological denitrification, and biological phosphorus
removal.

This course provides discussion of and detailed examples of process design

calculations for a single stage BOD removal MBBR system, a single stage tertiary
nitrification MBBR system, a two-stage BOD removal MBBR system, a post-anoxic
denitrification MBBR system and a pre-anoxic denitrification MBBR system.
14. References
1. Odegaard, Hallvard, Compact Wastewater Treatment with MBBR, DSD

International Conference, Hong Kong, 12, 11-14-2014.
http://www.dsdic2014.hk/ppt/Presentation_(B4-1).pdf
2. Odegaard, H., The Moving Bed Biofilm Reactor, in Igrarashi, T, Watanabe, Y,

Asano, T, and Tambo N., Water Environmental Engineering and Reuse of
Water, Hokkaido Press 1999, p 250-305/
3. Steichen, M. & Phillips, H., Black & Veach, Process and Practical
Considerations for IFAS and MBBR Technologies,Headworks International
Presentation, 03/18/2010.
4. Rusten, B. and Paulrud, B, Improved Nutrient Removal with Biofilm Reactors,

Aquateam Norwegian Water Technology Center, Oslo, Norway.
5. McQuarrie, J.P. and Boltz, J.Pl, Moving Bed Biofilm Reactor Technology:
Process Applications, Design and Performance, Water Environment Research,
Vol 83, No. 6, June 2011.
6. Bengtson, Harlan H., MBBR Wastewater Treatment Design Spreadsheet, An

online article at www.EngineeringExcelSpreadsheets.com .
7. Bengtson, Harlan H., Spreadsheets for MBBR Wastewater Treatment Process

Design Calculations, an Amazon Kindle e-book.
8. Bengtson, Harlan H., Spreadsheets for MBBR Denitrification Design

Calculations, an Amazon Kindle e-book.

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A SunCam online continuing education course

MBBR Wastewater Treatment Processes

Harlan H. Bengtson, PhD, P.E.

www.SunCam.com Copyright 2017 Harlan H. Bengtson Page 2 of 49

At the conclusion of this course, the student will

Be familiar with the general configuration and components of an MBBR

Be able to calculate the loading rate of a wastewater constituent to an MBBR

Be able to calculate an estimated effluent BOD, NH3-N, or NO3-N concentration

www.SunCam.com Copyright 2017 Harlan H. Bengtson Page 3 of 49

Be able to make process design calculations for a post-Anoxic denitrification

Be able to make process design calculations for a pre-anoxic denitrification

3. Topics Covered in this Course

I. General Information about the MBBR Wastewater Treatment Process

A. Initial Development of the Process

II. MBBR Process Design Calculations BOD Removal and Nitrification

A. Overview of MBBR Process Design Calculations

III. MBBR Denitrification Processes

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A. Introduction to MBBR Denitrification Processes

4. General Information about the MBBR Wastewater

Initial Development of the Process

General Description of the Process

The MBBR process is an attached growth biological wastewater treatment process.

www.SunCam.com Copyright 2017 Harlan H. Bengtson Page 5 of 49

The MBBR Media Support Carrier System

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MBBR Process Alternatives

1. Single stage BOD removal

www.SunCam.com Copyright 2017 Harlan H. Bengtson Page 7 of 49

6. Post-Anoxic BOD removal/Nitrification/Denitrification

Figure 4. MBBR Wastewater Treatment Process Alternatives

www.SunCam.com Copyright 2017 Harlan H. Bengtson Page 8 of 49

5. MBBR Process Design Calculations for BOD Removal

Overview of MBBR Process Design Calculations

Single Stage BOD Removal Process Design Calculations

An MBBR single stage BOD removal process may be used as a free-standing

www.SunCam.com Copyright 2017 Harlan H. Bengtson Page 9 of 49

Figure 5. Single Stage MBBR Process for BOD/COD Removal

The equations for making those calculations are as follows:

1. BOD loading rate = Q*So*8.34*453.59

2. required carrier surface area = BOD Loading Rate/SALR

where: BOD Loading Rate is in g/day

www.SunCam.com Copyright 2017 Harlan H. Bengtson Page 10 of 49

The calculated required carrier surface area will be in m2.

3. required carrier volume

where: required carrier surface Area is in m2

4. required tank volume = required carrier volume/carrier fill %

Use of an Excel Spreadsheet

www.SunCam.com Copyright 2017 Harlan H. Bengtson Page 11 of 49

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Figure 6. Screenshot Single Stage BOD Removal Calculations U.S. units

a) What is the BOD loading rate to the reactor in g/day?

c) Required carrier surface area = (136,260 g/day)/(7.5 g/m2/day) = 18,168 m2.

d) The volume of liquid in the reactor can be calculated as:

e) The HRT at design ave ww flow can be calculated as:

HRTpeak hr = HRTdes ave/peak hour factor = 145/4 = 36 min

www.SunCam.com Copyright 2017 Harlan H. Bengtson Page 13 of 49

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Figure 7. Screenshot Single Stage BOD Removal Calculations S.I. units

1. BOD loading rate = QSo8.34*453.59