Two Kaldnes moving bed biofilm reactor (MBBR™) full scale treatment plants were commissioned in 1999, following successful pilot tests which generated the design data. The MBBR plants are incorporated into each facility as roughing reactors ahead of existing activated sludge processes. Results from the first three months of operation at the Phillips refinery showed surfa ce area loading rates (SALR) averaging 27 g COD/m2/day or twice those seen in the pilot study while percent removals remained constant at 62%. Performance at the Valley Pride Pack facility showed >90% removal of soluble BOD at SALR of 20 g/m2/day in one reactor while nitrification removal rates up to 0.83 g NH3–N/m2/day have been seen in the second stage of the MBBR treatment system.

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