IFAS Process for Nitrogen Removal.

Practical
Experiences and Guidelines for Design, Modelling and
Operation for Treating a Mix of Municipal and Industrial
Wastewaters

M. Huhtamäki*, D. Sen**
*Juurocon Oy, Alitalontie 11, FIN-21110 Naantali, Finland (E-mail:
juurocon.oy@dnainternet.net)
**Santa Clara Valley Water Authority, 5750 Almaden Expressway, San Jose, CA 95118

Abstract: The IFAS processes have proved their effectiveness and the number of references
is increasing rapidly. The special features of IFAS process for plant designers and operators
are described. A case based on real data is modelled and simulated under different
conditions. One of the results was that lower environmental load with lower costs could be
achieved at the municipal wwtp, if the industrial effluent pre-treatment would be by-passed.
This was verified also in practice. Practical general guidelines are given for process design
and optimisation based on the global technical experiences as well as on the simulation work.

Keywords: Biofilm; IFAS; modelling; nutrient removal

Introduction
Integrated fixed film activated sludge process (IFAS) utilizes the benefits of activated sludge
process and MBBR. The hybrid process is more compact, flexible and stable. The biofilm
processes are often characterised by better sludge settling properties and better capability to
handle toxic shock loads. These features are verified in plants having parallel lines both for
IFAS and activated sludge processes. E.g. at Windsor Lock, CT (Hubbell and Krichten 2004)
Except the ammonia removal, better SVI test results and improved recovery from shock
loads and plant upsets was noticed in IFAS line. Total nitrogen concentration of 8 mg/l was
reached with IFAS-process (web type media) at 12 oC and 2.5 h HRT.
Several types of media available for IFAS systems fall in two categories: fixed and
dispersed media. These are categorized in table 1. The process was patented over 70 years
ago by Tholin and La Grange (1937). The sponge type of media, which was applied at that
time are still on markets by several suppliers. Alternative media types have been developed
actively and the number of IFAS references have increased remarkably during the last years.

Methods
The process modelling, simulation and optimisation described here are based on a high
loaded biological process with about 6 hours residence time. The main flow comes from
municipal sources. In addition industrial effluent with various pre-treatment alternatives is
taken to the town wwtp. The wwtp of Raisio, Finland was selected to the basis for the

© IWA Publishing 2006. Published by IWA Publishing, London, UK.

2 M. Huhtamaki and D. Sen

evaluation due to several reasons. In the process there are two lines equipped with on-line
analysator for NH4-N, NO3-N, PO4-P and MLSS. In addition a lot of data exists for the
process evaluation. The process was originally a fully aerated AS plant, then converted to a
DN-process and later to a 4-stage Bardenpho process equipped with biofilm media. The plant
has been loaded with food industry effluent, which is pre-treated on different ways covering
anaerobic process, activated sludge process, aerated buffer tank and only mechanical pre-
treatment. The demonstration was partly financed from EU-Life Environment This is a
plentiful case for testing a simulation model under different conditions.
The used simulation model is described in detail by Sen et al (2007). The model is tested
for several types of processes and conditions. Sen et al (2006) evaluated ten full scale
wastewater treatment facilities applying the model. The analysis showed that the model was
able to accurately predict the performance of the facilities.

Results and discussion

Plant design
Simulation and process optimisation
In the IFAS-system two different biological processes have to be taken into account. The
sludge age of the free activated sludge is typically 4 – 7 days but on the fixed media on the
same time often more than one month. Typical biofilm developed on the carriers is shown in
figure 1. In this example the SRT of activated sludge is less than 2 days and including the
biomass on the media about 3 days. In biofilm can be seen such microbial population, which
would require in activated sludge process one months sludge age. This results in the fact that
the biofilm can nitrify also when the activated sludge does not (Huhtamäki 2006). The
character of the biofilm processes should be understood and the process dimensioning based
on models, which take into account simultaneously the both processes.
.

Figure 1. Typical biomass population growing on biofilm media

Construction of the process

The selection of biofilm media type - fixed-in-place types (web-type, rope-type and PVC
sheet media) or dispersed types (sponges or hard plastic particles) – determines if
intermediate screens are required and how the aeration can be placed.
The role of pre-screening is important for the biofilm processes. Hairs and fibrous
substances stuck easily on the media and intermediate screens. If the intermediate screen is
mesh type, it is strongly advised to have also mesh or hole type screens in pre-treatment.
Effective pre-separation of SS improves the capacity of the process. In case of risk for
high SS load or variation especially compared to soluble N-concentration a primary
clarification should be installed.
 M. Huhtamaki and D. Sen 3

The aeration has to be intensive enough to get the a good turbulence on the biofilm
surface and to mix the carriers in the sections. Each media type has its own requirements for
aerator placing. The mixers in anoxic sections should be gentle enough in order not to break
the media. Often biofilm media is not installed to the anaerobic and anoxic sections.
The structure of biofilm media, mixing and aeration have a major effect on turbulence and
mass transfer on the biofilm surface. However, only very limited information is available
from these effects for nitrification. The effect of turbulence to the oxygen profile in the
biofilm has been studied by Nagaoka and Sanda (2005).

Nitrogen and phosphorous removal

The biological P- and N-removal can be constructed on several ways. These are described
e.g. by Metcalf & Eddy (2003).
Biological phosphorous removal is not yet commonly applied because it is seen to be
quite unstable. Janssen et al (2002) have described biological phosphorous removal and the
phenomena behind it and analysed several plants in detail. Tight P-requirements can be
reached constantly without chemicals like Oud-Beijerland 0.1 mg P/l and Putte 0.2 mg P/l
and Hardenberg 0.2 mg P/l. In all cases, when the effluent nitrate is stable and below 6 mg/l,
also the effluent phosphorous level is low.
Biological phosphorous removal increased and stabilized using IFAS process. Rogalla et
al (2006) have described a full scale application, where the P is typically reduced from 10 to
0.5 mg/l. The process is described in detail by Johnsson et al (2006). The SS:BOD:N:P -ratio
is 170:100:20:4. The temperature varies from winter 14 oC to summer 22 oC. Biological P
removal was effective on the whole temperature range with less than 4 days aerobic sludge
age providing nitrate concentration was stabile and below 8 mg/l.
Often a phosphous concentration level of 0.1 – 0.3 mg P/l can be reached without tertiary
treatment. Jokinen (2005) has described results and methods, how P-removal is improved in
secondary treatment using polymers. In case the hydraulic retention time or SRT is short, the
use of simultaneous percipation should be minimised.
Flotation has widely replaced the sand filtration in potable water treatment. Still it is
seldom used at wastewater treatment although the effectiviness is at least on the same level
as with sand filtration. The benefit is that flotation can be used also for by-pass water
treatment and it tolerates high solid loads. The separation efficiency for SS and P are high
but also >90% BOD removal is reached in Raisio. The experiences from the studied 58
Norwegian flotations plants used for primary clarification are similar (Odegaard 2003).
At Raisio these resuls have been achieved in full scale with a surface load of 9 m/h. The
chemical selection has to be done case by case.

Operation and optimisation of the IFAS process

The simulation produces valuable information for the plant in adapting the operational
parameters to the actual situation – the load and water quality and their fluctuation. The
optimal parameters for biological nitrogen and phosphorous removal depend amongst other
things on water temperature.
If there is a pre-clarifier in the plant, an efficient solid separation helps the operation of
the biological process especially if the SRT is short and if the solid load varies widely.
If the solid removal from the pre-clarifier fails or the sludge dewatering is insufficient the
internal solid load may interfere with the biological process. The separation efficiency can be
increased by adding metal coagulants. Addition of suitable polymer increases the solid
separation efficiency even more.
4 M. Huhtamaki and D. Sen

Mixing is necessary to maintain the proper biofilm thickness. Insufficient mixing

increases the biofilm thickness which reduces the active biofilm surface area and produces
conditions optimal for worms to grow. As a result the nitrification decreases. Conversely,
excessive mixing and collision (with walls, other media) can prevent formation of biofilm.
pH has to be monitored and when needed, regulated to 7.0 – 8.5. The nitrification rate
decreases rapidly when pH decreases below 7.0.

Process and simulation data

The measured and simulated data were verified to be comparable. Alternative control
principles, process configurations, loads and process conditions were simulated.

Process data
The nitrogen load and reductions as monthly averages, the operated process mode at the
Raisio town wwtp and periods when a major fraction of industrial effluent load consists of
mechanically pre-treated effluent are shown for the past six years in figure 2.
Nitrogen removal bound to sludge kg/month
Nitrogen removal to/from air (= influent - effluent - sludge N) kg/month
Environmental load NO3-N kg/month
Environmental load NH4-N kg/month
kg N/ IFAS, Fully aerated MBBR; DN
month Line 1
AS; Fully aerated AS; DN-process - IFAS; DN Line 2
25 000
Normal load B D

20 000

15 000

10 000

5 000

-5 000
1 2001
2 2001
3 2001
4 2001
5 2001
6 2001
7 2001
8 2001
9 2001
10 2001
11 2001
12 2001
1 2002
2 2002
3 2002
4 2002
5 2002
6 2002
7 2002
8 2002
9 2002
10 2002
11 2002
12 2002
1 2003
2 2003
3 2003
4 2003
5 2003
6 2003
7 2003
8 2003
9 2003
10 2003
11 2003
12 2003
1 2004
2 2004
3 2004
4 2004
5 2004
6 2004
7 2004
8 2004
9 2004
10 2004
11 2004
12 2004
1 2005
2 2005
3 2005
4 2005
5 2005
6 2005
7 2005
8 2005
9 2005
10 2005
11 2005
12 2005
1 2006
2 2006
3 2006
4 2006
5 2006
6 2006
7 2006
8 2006
9 2006
10 2006
11 2006
12 2006

Aver 2004
Aver 2005
Aver 2006
Aver 02 tests
2001 - 2002

Nitrogen fixation from air Yellow: Nitrogen removal >60% Raisio Plc pre-treatment by-
Green: Nitrogen removal >70% pass partly or totally

Figure 2. Nitrogen balance at Raisio wwtp during 2000 - 2006

When unaerated food industry wastewater was taken to the wwtp (DN-process and > 7.0)
the required 70% nitrogen removal was reached. The useful effect of the soluble BOD in
industrial effluents can be noticed even better by analysing the composite samples (figure 3).
During the period no other carbon sources were added. Methanol addition was started at the
end of January 2007 and 70% nitrogen removal was achieved. The analyses show clearly that
the denitrification is limited by insufficient easily biodegradable carbon source.
The optimal addition of BOD-sol is the amount, which would be needed as methanol
(mg/l) at the municipal wwtp. At that point the load replaces methanol without increasing
sludge production. Better nitrogen removal can be achieved if the load is higher. If it is
lower, some additional carbon source has to be added.
The pre-aeration of industrial wastewater with 12 hours residence time removed most of
the soluble BOD.
 M. Huhtamaki and D. Sen 5

90% Normal load

1.1.2001 - 1.6.2002
80% Test period B
1.8.2002 - 9.12.2002
70% Test period D
27.6.2003 - 30.11.2003
Nitrogen reduction

60%
- Normal load: At the wwtp both lines in
50% operation. At the industry an efficient
biological pre-treatment.
40% - Test periods B and D: Only line 2 in use in
which a 30 volume-% unaerated zone was
30% created by closing the aerator valves.
- During period B more soluble BOD was
discharged to the wwtp than during period
20% D. During period B the redox-potential in
the unaerated zone was all the time
10% negative but during period D it was
between -100 ... + 100 mV.
0%
0 5 10 15 20 25
Influent BOD7(ATU) /N-tot ratio

Figure 3. Nitrogen reduction versus industrial load and BOD/N relation during 2001 -2003

Simulation data
The simulations were done for the basic data according to table 1 corresponding the load
level of the evaluated plant from 2006 and real analytical and calculated data.

Table 1. Basic data for the simulations

Fraction
Municipal Ind. Mechanical Ind. Pre-aerated Ind. Aa+ aer.
fraction pre-treatment pre-treatment
Name kg/d mg/l kg/d mg/l kg/d mg/l kg/d mg/l
3
Flow norm m /d 11800 1700 1700 1700
Temperature oC * 8 15 * 15 * 15 *
COD-tot 7400 627 2810 1653 2213 1302 2213 1302
COD-sol 870 74 1645 968 247 145 71 42
BOD7-tot 2960 251 1555 915 942 554 43 25
BOD7-sol 300 25 1168 687 112 66 2 1
TSS 5000 424 1001 589 1311 771 85 50
VSS 3750 318 951 559 1245 733 68 40
N-tot 550 47 90 53 90 53 70 41
NH4-N 413 35 25 15 3 2 70 41
P-tot 105 9 51 30 52 31 2 1
PO4-P 63 5 31 18 27 16 1 0
*
Based on the effective temperature influent after drainage to the wwtp (winter time)

Based on the data, different situations were simulated e.g. for flow increase of wastewater
sources, pre-treatment alternatives of the industrial effluent, summer and winter conditions,
media filling ratios and recycle flows. The basin volume was fixed to 3600 m3, the MLSS
concentration (of free sludge) to 3 g/l and the process to a 4-stage Bardenpho process in
which the post-anoxic section can also be aerated, if needed. (The configuration is similar to
fig.4, except the anaerobic section.)
In figure 5 the key simulation results are shown in the case where industrial effluent is
discharged after screening and the process configuration is close to the existing one. From
6 M. Huhtamaki and D. Sen

the figure can be seen, that the post-anoxic department is inefficient for denitrification
without carbon source addition. At this load it is not needed for 70% nitrogen removal or 15
mg/l residual nitrogen.
Me3+ or Me3+
Me2+

AnaerobicAnoxic Aerobic Anoxic

Me3+

Figure 4. A typical BRN-plant and alternative places to add coagulant when needed

Eff SCODbio Eff NH4N Eff NO3N Flow

NH4N Uptake in Biofilm and MLVSS (kg/d)
b) Flow, m3/h
SCODbio, NH4N, NO3N conc, mg/L

12 mg/l 16 000
NH4-N 0,2 200
NO3-N 9,6 mg/l
TN-out
14 000
10 11,50 mg/l 180
TN-in 54,7 mg/l 12 000
160 Mixed Liquor VSS
8
10 000 Biofilm
NH4N Uptake, kg/d

140
6 8 000
120
6 000
4 100
4 000
80
2 2 000
60
0 0
40
10 12 14 16 18 20 22 0 2 4 6 8 10
Time of the day N to prim. sludge 11960 m3/d
20
20 %
N to secondary sludge 19 % 0
AA

Anox

Anox

Aer

Aer

Aer

Anox

Anox

Aer

Aer
N as gas to air
-

-
79 %

Load Munic. Ind Sum clarif. out Denitrification in Biofilm and MLVSS

Q m3/d 10000 1700 11700 11965 11700 200

180 Mixed Liquor VSS
SS kg/d 5000 1001 6001 1214 117 160 Biofilm
Oxidized N Denitrified, kg/d

VSS kg/d 3750 951 4701 928 88 140

120
COD kg/d 7400 2810 10210 3536 123 100
80
BOD kg/d 2960 1555 4515 1775 35
60
P-tot kg/d 105 51 156 36 16 40
20
N-tot kg/d 550 90 640 508 136 0
AA

Anox

Anox

Aer

Aer

Aer

Anox

Anox

Aer

Aer
-

NH4-N kg/d 413 25 438 450 3

NO3-N kg/d 1 0 1 1 112

Figure 5. Effluent quality. Conditions: Load 100% basic load; Industr. Mech. pre-treated;
Basin: 25% pre-anoxic, 52,5% aerobic, 20% post-anoxic and 2,5 % post-aeration; RAS 125%;
NR 75%; Media 200 m2/m3 in each cell except in the first post-anoxic cell.

The variation of ammonium and nitrate concentration in the situation, when the municipal
load is 30% and industrial load 50% higher than today are shown in figure 6. The alternatives
with and without efficient pre-treatment are evaluated. The simulation shows that 70%
nitrogen removal can be achieved if the industrial effluents would be discharged after
screening. The post-anoxic section should be aerated in order to oxide ammonium better.
Interesting is that if the industrial effluent would be pre-treated anaerobically, even with
 M. Huhtamaki and D. Sen 7

methanol addition at that load 70% nitrogen removal can not be reached and also the
recipient nitrogen load is higher in that alternative.
A fraction (5 – 15%) of the pre-clarified water can be taken to the post-anoxic section. It
reduces the oxygen concentration in the recycle streams and may reduce the risk for bristle
worms. This has only a minor effect on nitrogen removal. The simulation can also be used
for optimising the oxygen concentrations and recycle streams. High oxygen concentration in
the aeration increases oxygen load to denitrification through recycle flows. These parameters
can be optimised for nitrogen removal by using the process simulation.

Eff SCODbio Eff NH4N Eff NO3N Flow Eff SCODbio Eff NH4N Eff NO3N Flow
a) Flow, m3/h b) Flow, m3/h

SCODbio, NH4N, NO3N conc, mg/L

SCODbio, NH4N, NO3N conc, mg/L

9 mg/l 900 12 m g/l 900

NH4-N 4,5 NH4-N 2,7
8 NO3-N 7,4 mg/l 800 NO3-N 8,8 m g/l 800
TN-out 15,72 mg/l 10 TN-out 14,78 m g/l
7 TN-in 54,7 mg/l 700 TN-in 54,7 m g/l 700
6 600 8 600
5 500 500
6
4 400 400
3 300 4 300
2 200 200
2
1 100 100
0 0 0 0
10 12 14 16 18 20 22 0 2 4 6 8 10 10 12 14 16 18 20 22 0 2 4 6 8 10
Time of the day
Time of the day N to prim. sludge 19 % 15955 m3/d N to prim . sludge 19 % 15986 m3/d
N to secondary sludge 23 % N to s econdary sludge 21 %
N as gas to air N as gas to air
71 % 73 %

Eff SCODbio Eff NH4N Eff NO3N Flow Eff SCODbio Eff NH4N Eff NO3N Flow
c) Flow, m3/h d) Flow, m3/h
SCODbio, NH4N, NO3N conc, mg/L

SCODbio, NH4N, NO3N conc, mg/L

35 mg/l 900 20 mg/l 900

NH4-N 2,1 NH4-N 3,2
NO3-N 23,1 mg/l 800 18 NO3-N 11,8 mg/l 800
30 TN-out 28,53 mg/l TN-out 19,13 mg/l
TN-in 700 16 TN-in 700
52,8 mg/l 52,8 mg/l
25 14
600 600
20 12
500 500
10
15 400 400
8
300 300
10 6
200 4 200
5 100 100
2
0 0 0 0
10 12 14 16 18 20 22 0 2 4 6 8 10 10 12 14 16 18 20 22 0 2 4 6 8 10
Time of the day 15788 m3/d Time of the day N to prim. sludge 15823 m 3/d
N to prim. sludge 12 % 12 %
N to secondary sludge 13 % N to secondary sludge 16 %
N as gas to air N as gas to air
46 % 64 %

Figure 6. Effluent quality. Conditions: Municipal 130%; Industry 150%. a) and b) Ind. ww
mech. pre-treated; c) and d) Ind. anaerobically pre-treated; Conditions like in fig 5 except in
6b) post anoxic section is aerated; NR=0; RAS=180% and in 6d) 60 g/m3 methanol is added.

Eff SCODbio Eff NH4N Eff NO3N Flow

Load Munic. Ind Sum clarif. out b) Flow, m3/h
SCODbio, NH4N, NO3N conc, mg/L

3
Q m /d 17700 3400 21100 21673 21100 9 NH4-N
NO3-N
2,0
6,9 mg/l
mg/l 1 200
8
TN-out 11,35 mg/l 1 000
SS kg/d 6750 2002 8752 2854 211 7 TN-in 43,8 mg/l
6 800

VSS kg/d 5063 1902 6964 2176 158 5

600
4
COD kg/d 9990 5620 15610 7254 222 3 400
2
200
BOD kg/d 3996 3110 7106 3662 63 1
0 0
P-tot kg/d 142 102 244 80 29 10 12 14 16 18 20 22 0 2 4 6 8 10
Time of the day 21672 m3/d
N to prim. sludge 18 %
N-tot kg/d 743 181 923 755 239 N to secondary sludge 28 %
N as gas to air
74 %
NH4-N kg/d 557 50 607 637 42
NO3-N kg/d 1 0 1 1 146

Figure 7. Effluent quality. Munic. load 135% and flow 150%; Industry 200% mech. pre-treated

When simulating even higher loads e.g. as described in figure 7 can be seen that the flow
and the industrial load could be increased remarkably if the existing process volumes would
be fully utilized. In the situation described in figure 7, nitrogen load of the biological section
8 M. Huhtamaki and D. Sen

is 0.2 (kg N/d)/m3, HRT 4 hours, temperature 9 oC and aerobic sludge age 2,5 days. Under
these conditions the sludge treatment and hydraulic capacities are exceeded although the
biological treatment would have the possibilities for the required reduction.

Conclusions
A proper simulation model is a valuable tool for the system design and optimisation of the
results. The IFAS process utilises both the activated sludge and biofilm media. Due to
different characters of the biomass in the activated sludge and in the biofilm, these have to be
calculated separately and parallel to each other.
An efficient pre-screening is a must.
Both the municipality and the industry could benefit, if the biological pre-treatment is
reduced in a way that the soluble BOD can replace the used methanol at municipal wwtp.
Carrier type of media has more specific surface area than other IFAS media types. Despite
of hundreds of references in carrier processes, the mechanical solutions and design practices
need to be developed further. Open discussion and change of experiences are needed.
Biological P removal can be increased and stabilized for BNR-plants by adding biofilm
media especially in the aerobic section to improve nitrification and denitrification.

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