Dynatec News

Reuse Water with MBR

High-quality discharge and reuse from MBR

Dynatec Provides Reuse Water for Cereals Plant

Dynatec Systems, Inc. has installed a water reuse system in a major cereals plant in Georgia.

The complete treatment system, consisting of a membrane bioreactor (MBR), followed by reverse osmosis (RO), provides a net savings to the plant of more than $3,000 per day in water and sewer charges after deduction of the plant operating costs. The water is reused for cleaning, in scrubbers and in boilers.

Previously, the facility discharged all the wastewater to a municipal treatment plant at a rate of up to 0.5 mgd, and paid both volume and load charges

Quality Criteria

Since the plant produces a food product, ultimate water quality is vital. The two-stage membrane system (MBR + RO) and final sterilization with ultraviolet (UV) treatment provides the quality assurance that plant management requires. In addition, the membranes used in the MBR system are external to the aeration basin and are tubular. This type of membrane is much less susceptible to failure than the immersed type.

System Design

After a review of the available treatment options, the owners of the facility chose the Dynatec bioreactor option. This process combines aerated biological treatment with an out-of-basin ultrafiltration (UF) system. In combination with reverse osmosis treatment, Dynatec was able to provide the client with the necessary assurances that the water quality would not be compromised, and that the water would be suitable for process purposes, such as boiler feed water.

Dynatec’s design consisted of the following components:

• Internally fed rotary screen
• 500,000 gallon above-ground stainless steel equalization tank with jet aeration and duplex PD blowers
• 500,000 gallon above-ground stainless steel aerated biological reactor with jet aeration and triplex PD blowers
• Four membrane skids with a common automated CIP (clean-in-place) system, one skid operates in standby mode
• Reverse Osmosis system
• Final UV (ultraviolet) sterilization
• Sludge dewatering decanter centrifuge
• Completely integrated control system managing all system functions

System Advantages:

• The system provides many advantages for the operators and owners.
• Redundant membrane skids for ease of operation and cleaning.
• Simple automated cleaning operations with membranes in place.
• High mixed liquor concentration ensures the lowest possible sludge production, and requires smallest possible footprint.
• Simple, low maintenance system.
• Long-lasting tubular membranes with 0.03 μm membrane, ensuring removal of bacteria and viruses.

Results:

The system has produced high quality water for reuse. Consistently, the water quality from the MBR has been as follows:

State Award
The facility received an award from the State of Georgia Association of Water Professionals presented an award to the
facility for Outstanding Operation of a facility in the category of Water Conservation.

Project Conclusion:
The project was completed on time and within budget, and has exceeded the estimates that were initially made for cost savings.
The Dynatec system has proved to be reliable and efficient, and has exceeded the customer’s requirements, based on the initial
projected performance.

Technology Benefits

Biological treatment using Membrane Bioreactors provides several benefits:

• Consistently high-quality water
• No upsets, since the membrane provides a positive barrier to bacteria and viruses
• Smaller footprint than conventional systems, due to operation at high levels of mixed liquor
• Better system kinetics than conventional systems, due to long sludge age
• Complete removal of bacteria and viruses
• High quality water for reuse
• Dynatec Out-of-Basin MBR Systems:
• Operators never come in contact with biomass
• Easy clean-in-place without moving membranes

https://www.dynatecsystems.com/industries/food-and-beverage/

ZLD wastewater treatment system

ZLD wastewater treatment system for a food processing company was provided by Dynatec. The primary treatment is provided by a tubular membrane bioreactor (MBR) followed by reverse osmosis (RO). Membrane bioreactor permeate is reused for cooling tower make up. Reverse osmosis permeate is re-used for high-quality users and reverse osmosis (RO) reject is used for irrigation.

ZLD wastewater treatment system

Recovery and reuse systems have been provided by Dynatec Systems to many industries. The ability to recover and reuse water has many benefits.

• Saving on water costs
• Saving on wastewater disposal charges
• Decreased environmental impact
• Protection from regulatory changes
• Decrease dependence on water provider/source
• Ability to expand without affecting water demand
• Overcome water scarcity issues
• Consistently high-quality for water reuse

Ultrafiltration (UF), Membrane Bioreactor (MBR), Nanofiltration (NF) and Reverse Osmosis (RO) are employed by Dynatec for water reuse projects. Water recovery and water reuse has been successfully implemented with industrial and sanitary wastewater streams for:

• Cooling tower make up
• Boiler feed
• Irrigation
• Toilet flushing
• Direct potable reuse
• Cleaning/wash applications
• Rinse processes
• Painting processes
• Other plant processes

Recovery and reuse systems provided by Dynatec Systems: 

• Resorts, hotels, and retirement homes
• Golf courses
• Automotive companies
• Food and beverage companies
• Apartment buildings
• Landfills
• Mines
• Metal finishing plants
• Aerospace companies

Membrane Bioreactors

Membrane bioreactors offer a unique and effective solution for the treatment and reuse of industrial wastewater in industries such as landfills, automotive, aerostructures, distilleries and dairies. Our industry-leading designs and innovation also deliver superior performance for sanitary wastewater and biological nutrient removal applications.

The MBR configuration has proven to be optimal for treatment of many industrial wastewaters when treatment efficiency is an important consideration.

The MBR is the ideal bioreactor configuration for treatment of organic or inorganic contaminants present in industrial wastewaters. MBRs operate at a higher efficiency while achieving consistent design performance objectives. This makes MBR a more cost effective method of treatment when performance and tank requirements are considered.

Bioreactor systems such as the conventional activated sludge system, sequencing batch reactor system and trickling filters are typically designed for operation at a lower volumetric removal rate, requiring larger tanks and more space. These conventional systems often experience upsets that inhibit settling and therefore require much more operator attention than a membrane bioreactor.

The MBR has proven to be optimal for treatment of many industrial wastewaters because it is less susceptible to upsets. The MBR’s performance is not affected by changes in sludge settleability like the conventional systems, making MBR a wise choice for industrial systems that have more difficult to treat waste streams. Dynatec has over 45 years experience in dealing with difficult to treat industrial wastewaters using membrane filtration.

For more information on zero-liquid discharge (ZLD) wastewater treatment systems, please contact us today.

https://www.dynatecsystems.com/technologies/recovery-and-reuse/

Landfill Leachate treatment system

Landfill leachate treatment system for a hazardous waste landfill incorporates heavy metals pretreatment followed by a tubular MBR system. 

The MBR reduces:

• ammonia
• phenol
• Polychlorinated Biphenyl (PCB)
• chemical oxygen demand (COD)
  

  

• volatiles and semi-volatiles
• and other contaminants adequately for discharge  

The system reduces PFAS 30-60% and carbon is utilized to reduce PFAS to low ppt concentrations.

Landfill leachate treatment systems with Membrane Bioreactors (MBR)s have developed many unique process improvements for industrial wastewater applications. Dynatec successfully uses Ultrafiltration (UF), MBR and Reverse Osmosis (RO) for landfill leachate applications.

Landfill leachate treatment system requirements

Treatment can vary, depending on the discharge requirements, and the contaminants present

Landfill leachate is characterized by:

• High Total Dissolved Solids (TDS)
• Heavy metals
• High BOD
• Color
• High COD
• High ammonia

Landfill leachate treatment systems options

The MBR option: an aerated biological mixed liquor process operating at very high solids concentrations. 

The advantages are:

• Long sludge age produces a well acclimated biomass. High concentration (typically 12,000 to 20,000 mg/l) provides very high rates of reaction
• Excellent nitrification and de-nitrification
• Smaller footprint then conventional aerated systems
• High-quality effluent as a result of using membranes for final clarification
• Lower sludge production than conventional systems

Typical MBR results in landfills: 

The system produces bio-sludge, which can either be dewatered for disposal, or disposed of as a liquid sludge.

Alternative landfill leachate treatment options: 

• Chemical precipitation of metals before MBR treatment
• RO after MBR treatment removes organic and inorganic contaminants, and color
• UF followed by RO

The two effluent streams from a RO system are:

• Permeate
• Concentrate (or reject)

This can be re-injected into the landfill.  Its long-term effects on leachate concentrations should be considered.

Conclusion

The MBR process provides the highest possible levels of organic removal with essentially zero suspended solids in the effluent. This is the ideal feed system for RO treatment.

RO permeate can be used for other non-potable purposes:

• Irrigation
• Truck washing
• Dust control

Dynatec membrane treatment systems have successfully provided outstanding performance in many landfill leachate applications. Considerations for this technology include:

• Membrane treatment offers reliable, consistent landfill leachate 
• Systems are highly cost effective, and require low levels of operator interface
• The best membrane system configuration for each application should be individually evaluated
• Membrane treatment is broadly applied in the US and abroad

Contact Dynatec Systems today to discuss your landfill leachate treatment solution.

https://www.dynatecsystems.com/industries/landfill-leachate-treatment/

MBR Leachate Treatment System

Prior to employing the Dynatec MBR leachate treatment system, the landfill was hauling all of their leachate. In 2010, the facility spent over $4,500,000 hauling 10,350 truckloads of raw leachate.

The landfill leachate was pumped from four different pump stations each with a different landfill contributory area. Analysis of the historical data showed the size of the contributory area and age of the landfill area played significant roles in flow and leachate quality. A few historical trends were identified and used to predict flows in a future landfill development scenario.

The MBR leachate treatment system was designed for the peak nitrification requirements of the influent. A large SRT (solids retention time) was selected to target the slowly biodegradable COD found in leachate due to long chain organic molecules that are more difficult to remove.

The system was designed with flexibility in mind. The MLSS can be increased to 20,000 mg/L in the system without affecting the oxygen transfer efficiency thanks to the jet aeration system selected, which enables the long SRT.

Dynatec’s industrial MBR is the ideal bioreactor configuration for treatment of organic or inorganic contaminants present in industrial wastewaters. MBR’s operate at a higher efficiency while achieving consistent design performance objectives. This makes MBR a more cost effective method of industrial wastewater treatment when performance and tank requirements are considered.

Industrial Membrane Bioreactors Benefits:

• Higher flux
• Lower costs
• Better membranes
• Improved permeate quality
• Less operator attention and maintenance

Contact Dynatec Systems today to discuss your landfill leachate treatment system.

https://www.dynatecsystems.com/industries/landfill-leachate-treatment/

SBR to MBR Conversion

SBR to MBR Conversion

Dynatec provided tubular ultrafiltration systems as part of an SBR to MBR conversion. The upgraded treatment system allowed the facility to meet all discharge requirements and increased the capacity of the plant. The SBR could treat 4,000 barrels per day and the upgraded plant utilizing an out-of-basin MBR treats up to 10,000 barrels of wastewater per day.

To meet direct discharge limits, the oil refinery needed to upgrade their treatment system. The existing SBR could not handle the volume of wastewater and was not consistently meeting the discharge quality limits.

The MBR reduced the COD to below 50ppm and phenols are reduced from over 750ppm to non-detect.

The solution for this plant was an oil water separator followed by out-of-basin membrane bioreactor (MBR).  The permeate from the MBR met all requirements for discharging to sea water. COD in the permeate was less than 300ppm. Phenols in the permeate were consistently less than 1ppm.

Dynatec provided containerized systems for easy and fast installation at site.

Significant Savings

• Simple process
• Fewer chemicals needed
• Low maintenance

Technology Benefits

• Consistent high-quality water
• Low operating costs
• Minimal operator intervention required
• Reduced sludge disposal costs

Contaminants Removed

• Oil and grease
• Heavy metals
• COD
• BOD
• Suspended solids
• Phenols

Flexible Retrofits

Since the membranes were installed outside the reactor, the membranes allowed for easy retrofit to any bioreactor configuration (circular, rectangular, above or below ground), .  Frequently, the existing infrastructure and building space can be reused with little or no changes.

Expandability

The membrane system is easy to expand, since the out of basin configuration allows for simple addition of more membranes, or membrane skids.

Better Performance

The MBR System eliminates many of the unit processes associated with conventional treatment systems. The bioreactor tanks degrade constituents normally considered recalcitrant and they eliminate solids carry-over from occurring, allowing long sludge retention times.

Contact Dynatec to discuss your application.

https://www.dynatecsystems.com/technologies/membrane-bioreactors/mbr-conversion-r…pgrade-solutions/ ‎

Anaerobic MBR with Dynatec Tubular UF Membranes

Maximizing Efficiency & Sustainability in Industrial

Wastewater Treatment

Why Choose Anaerobic MBR?

Anaerobic Membrane Bioreactor (AnMBR) technology is revolutionizing industrial wastewater treatment by combining anaerobic digestion with advanced membrane filtration. This cutting-edge process enables industries to achieve superior wastewater treatment while generating biogas for energy recovery.

The Dynatec Advantage: Tubular UF Membranes Dynatec’s tubular ultrafiltration (UF) membranes are at the core of our AnMBR systems, offering unmatched performance in treating high-strength wastewater.

These membranes provide:

Superior Solids Handling –

Handles high mixed liquor suspended solids (MLSS) without frequent cleaning or fouling.

Consistent Permeate Quality –

Achieves exceptional effluent quality with low turbidity and high removal of contaminants.

Robust & Durable Design – Built to withstand challenging industrial wastewater conditions.

Minimized Maintenance – Long membrane lifespan with reduced downtime and lower operating costs.

Key Benefits of Anaerobic MBR with Dynatec UF Membranes

1. Energy Generation & Cost Savings

– Converts organic matter into biogas, reducing energy costs.

– Eliminates the need for aeration, lowering power consumption significantly.

2. High-Quality Effluent for Reuse or Discharge

– Produces low-BOD and TSS effluent, meeting stringent discharge limits.

– Enables water reuse for non-potable applications, reducing water demand.

3. Compact Footprint & Modular Scalability

– Requires less space than conventional anaerobic treatment.

– Easily scalable to meet varying flow rates and loads.

4. Low Sludge Production & Reduced Handling Costs

– Generates minimal biosolids, lowering disposal costs.

– Reduces environmental impact and regulatory burdens.

Ideal Applications

– Food & Beverage Processing

– Agriculture / Manure

– Pulp & Paper Mills

– Pharmaceutical & Chemical Industries

– Landfill Leachate Treatment

-High-Strength Industrial Wastewater

Optimize Your Wastewater Treatment Today. Leverage the power of Anaerobic MBR with Dynatec’s tubular UF membranes for a sustainable, cost-effective, and energy-efficient solution.

Contact us today to learn how our advanced wastewater treatment systems can work for you.

Silver Recovery at Microcircuit Plant

The Problem

A microcircuit materials production facility produces high purity silver in their process. The process produces a wastewater stream containing valuable dissolved silver compounds. The plant had an existing membrane treatment system to recover the silver from the wastewater, but the system had performance problems, required excessive maintenance and chemical cleaning costs were high.

The Solution

When the plant expanded its operations, they performed an evaluation. The choice was between expanding the existing membrane system or installing a Dynatec membrane system designed for simple automatic operation with low operating costs. Dynatec was ultimately selected to provide a complete system because the Dynatec design offered a more reliable, easier to operate process. The installation includes transfer pumps, two reaction tanks, three ultrafiltration skids designed for 25 gpm each with room for expansion, a sludge conditioning system, and a filter press.

The Process

Wastewater from the process is stored in an equalization tank. Transfer pumps deliver the equalized wastewater to the first reaction tank where DTC (dithiocarbamate) is added to react with the aqueous silver compounds to form insoluble metal salts. The water then enters another reaction tank where the pH is adjusted to optimize precipitation of the silver compounds.

The precipitated silver compounds are then filtered in one of the three ultrafiltration skids. The ultrafiltration system, using tubular PVDF membranes are designed for automatic operation. When the membranes become fouled, the operator initiates an automatic cleaning, and the system performs a chemical membrane cleaning and the ultrafiltration skid is brought back into service.

The permeate from the ultrafilter is discharged and the concentrated silver is sent to a sludge conditioning tank where a high molecular weight cationic polymer is added to aid in filterability of the sludge. The sludge is then sent to a filter press and the cake is sent to a silver reclamation facility.

Conclusion

The installation of the new system was successful. The system has been operating for several years. Current operation at the plant consists of operating two filtration skids at a time with one as a standby. The system is designed to add capacity by simply adding membranes to the existing UF skids. Operators are happy with the system’s operation and the lower amount of maintenance and chemicals required.

Contact Dynatec to discuss your wastewater application.

https://www.dynatecsystems.com/industries/heavy-metals-removal/

Ultrafilter for Metals Removal

A metallurgy facility needed to remove metals from their wastewater. Bench scale treatability work performed by Dynatec proved the effectiveness of the ultrafilter (UF) system.  The UF system removed chromium, copper, zinc, nickel, and other metals to low parts per billion levels needed for surface water discharge.

The company produces ferrous metals (atomized steel and sponge iron) for use by auto parts makers and other manufacturers.  The steel and iron powders are used to make structural parts, filters, and bearings, as well as, in friction applications such as brake pads and linings. 

Dynatec has hundreds of installations in similar applications.

Ultrafilter for metals removal

Ultrafilter for metals removal can be achieved by chemical precipitation simply using hydroxide or sulfide precipitation. However, complexed metals have other chemistries available to cause precipitation to occur, typically in a simple one-step operation. There is no need to enlarge or flocculate the precipitated crystals, as is typical in conventional chemical systems since the pore structure of the membrane will retain the small precipitated crystals.

When oils are or may be present in the waste stream, the positive filtration provided by ultrafiltration prevents upsets that can occur with settlement or flotation devices. The membrane prevents passage of both oils and solids, including the precipitated heavy metals from passing, creating a concentrate of the metals.

If the waste stream consists principally of oils, a concentrate of the oils that will also contain the heavy metals is created that can be disposed of to oil recyclers. When the same type of waste is treated using DAF or clarifier technology, a sludge is created that can only be disposed to a landfill, and the benefit of reuse is lost and disposal is more expensive.

When the waste stream consists mostly of metals and suspended solids, the addition of a precipitant allows the waste to be simply ultrafiltered. The amount of sludge created is much less than the amount created using other technologies.

Dynatec’s design of ultrafiltration systems for heavy metals separation utilizes tubular membranes operated at high flow velocities. This design allows for high concentrations of metals and/or oils, and/or suspended solids in solution while minimizing cleaning maintenance of the membrane system.

Dynatec has provided systems for:

• Heavy metals removal
• Precious metals removal and recovery
• Complex wastewater streams

Ultrafilter for Metals Removal Solutions

• Ultrafiltration (UF) for metals removal 
  • Heavy Metals
  • Metals in wastewater with oils and grease
  • Precious Metals 
  • Metals in wastewater with chelating agents
• Ultrafiltration (UF) for reuse
• Reverse Osmosis (RO) for high purity water reuse
• Complete turnkey system solutions
• Filtration for sewer discharge of direct discharge to environment

Dynatec has designed and provided systems for reuse for:

• Wash water
• Rinse water
• Plant processes
• Cooling tower
• Boiler feed

Contaminants Removed

• Oil and Grease
• Heavy Metals
• Precious Metals
• Lubricants
• Surfactants
• Acids
• Biochemical Oxygen Demand (BOD)
• Chemical Oxygen Demand (COD)
• Suspended Solids
• Dissolved Solids

Please reach out if you have any metals removal projects that we can help with.

https://www.dynatecsystems.com/technologies/membrane-technologies/ultrafiltration-systems/

Landfill Leachate Treatment Expansion

Dynatec shipped two new Ultrafiltration systems for a landfill leachate treatment expansion project. These skids are part of an expansion at an existing leachate treatment plant. The existing Dynatec system treats 250,000 gallons per day. This expansion will allow them to filter 500,000gpd on average. The primary target contaminants at the landfill are heavy metals. The existing UF system has allowed the landfill to successfully reach their discharge limits for metals. Due to this success, they have contracted Dynatec as the leachate production has increased.

Dynatec Systems industry-leading tubular ultrafiltration (UF) system is used to treat a broad range of industrial wastewater by separating insoluble components from waste streams. As a cost effective and simple solution for separating insoluble components and colloidal contaminants from a waste stream, wastewater UF offers significant advantages over conventional separation. It is a useful process that does not require chemicals or much space to separate insoluble contaminants.

UF is a pressure-driven process that removes the following from wastewater and other solutions:

• Emulsified oils
• Metal hydroxides
• Colloids
• Emulsions
• Dispersed material
• Suspended solids
• Other large molecular-weight materials

Ultrafiltration systems are also capable of concentrating:

• Bacteria
• Some proteins
• Some dyes
• Colloidal or emulsified components

Ultrafiltration systems excels at the clarification of solutions containing:

• Suspended solids
• Bacteria
• High concentrations of macromolecules including:
  • Oil and water
  • Fruit juice
  • Milk
  • Whey
  • Electro-coat paints
  • Pharmaceuticals
  • Poly-vinyl alcohol and indigo
  • Potable water
  • Tertiary wastewater

Ultrafiltration offers the following advantages over conventional separation:

• No chemical required
• Very little labor required
• Simple mechanical process
• Less sludge
• Ability to concentrate the retentate for beneficial use
• Less space required
• Overall lower operating costs

Tubular Configuration:

• Higher permeate rate
• Lower rates of fouling
• Higher concentration of retentate
• Easier to clean
• Longer membrane life
• Low operating cost

https://www.dynatecsystems.com/industries/landfill-leachate-treatment/

Contact Dynatec for your landfill leachate treatment solution today.

Turnkey Solutions

Turnkey solutions provided by Dynatec include equalization tank, oil water separator, ultrafiltration (UF) process tank, UF system, and permeate and concentrate tanks. The customer, an industrial research facility, had a wastewater treatment facility that also treats the waste from several other manufacturers that occupy buildings nearby, recently purchased an UF system from Dynatec.  The UF system replaced a DAF system that was not effectively handling the contaminant load from these facilities, including oily waste, heavy metals, and suspended solids due to the frequent changes in the wastewater characteristics. The customer also chose to have Dynatec install the system. The UF system has allowed them to meet their discharge requirements with less operator attention and effort.

Dynatec’s team of mechanical, chemical and electrical engineers have decades of experience to provide everything you need, from start to finish. This includes evaluation, system design, installation, system startup and training. Our focus has always been to produce the most cost-effective long-term answer for our customer. All turnkey systems are custom designed and installed for your specific needs.

Two different sets of disciplines are employed for this stage of the process. First, years of process experience produce effective process design. Our ownership and operation of treatment systems produces invaluable field experience that is translated into operator-friendly equipment. Next, the process design is translated into a complete integrated treatment systems by our experienced engineering staff.

• Single source of responsibility
• Problem evaluation
• Process and system design
• Equipment
• Installation service
• System startup
• System startup consists of a three-step process:
  • The equipment is commissioned by proving each of the field instruments
  • The equipment is wet-tested
  • Equipment is operated on process fluid to prove operation under normal conditions
• Training by Dynatec engineers

Dynatec obtains membranes from a wide variety of suppliers, always aware of the need to produce lowest lifetime cost. Our suppliers produce membranes in a variety of materials, as well as a number of configurations for most effective solutions. In addition, Dynatec procures other equipment required to complete the project.

Dynatec manufactures modular equipment so that installation costs are kept to a minimum.  Supervised by experienced competent engineers. Our usual method of operation is to hire local contractors approved by our customer.

Proven Installed Turnkey Solutions

At Dynatec, we are not just experts in providing reliable equipment for industrial applications, we also provide the proven solutions that our global clients need.

For more information on our design-build turnkey solutions for your install, please contact us today.

https://www.dynatecsystems.com/engineered-installed-wastewater-treatment-and-recovery-plants/design-build-turnkey-solutions/