REACTION TANKS

THE ORBAL® SYSTEM FOR TrueSND™

BIOLOGICAL TREATMENT
SIMULTANEOUS NITRIFICATION–DENITRIFICATION FROM ENVIREX
THE ORBAL SYSTEM
The Orbal system was first introduced in 1968 and there are now over 800
installations. It is an important part of the Envirex® product line of Evoqua.
The Orbal® system is a reliable solution for enhanced nutrient removal,
Stormflow and energy management. It provides process flexibility to meet
today’s stringent effluent requirements.
SERIES OPERATION ENABLES TRUE KEY BENEFITS OF ORBAL® SYSTEMS
SIMULTANEOUS NITRIFICATION- TrueSND™ Biological Treatment
DENITRIFICATION (SND) TrueSND in the same zone results in 80%
denitrification without the need for an
The Orbal® system from Envirex is an activated sludge process designed to address internal recycle pump.
the nutrient and Stormflow issues of today. The Orbal® system has been on the
leading edge of implementing SND plant designs for over 20 years. With over 800 Eliminate Structures
installations it has been proven to deliver results. Allows for elimination of a dedicated anoxic
zone typically used in biological nutrient
NUTRIENT REMOVAL removal processes. This design saves the
associated treatment footprint, concrete
The simultaneous nitrification-denitrification (SND) process is the backbone of the
cost, mechanical mixers and operational
design. The Orbal® system incorporates a unique Concentric Loop™ configuration
energy cost for the mechanical mixer in the
that creates dedicated zones for specific treatment purposes. These treatment
anoxic zone.
zones operate in series which is essential to the SND process. The volume split of
the Concentric Loop configuration naturally applies the correct volume to oxygen Energy Efficient
input ratio required in the design of a SND plant. Operating a majority of the system volume
The Concentric Loops also save on concrete and construction costs of the aerobic at a strong oxygen deficit allows for
basin volume by using common wall construction. The SND design allows for the much higher oxygen transfer efficiency in
elimination of a dedicated anoxic zone, which saves further on construction costs. comparison with operating a system with a
2mg/l DO or greater throughout the process.
STORMFLOW
Process Adaptability/Flexibility
Operating tanks in series allows for diverting the Stormflow downstream of the first Adaptable to achieve lower TN or TP as
reactor, preventing clarifier washout of biomass and storing it in the first reactor of regulations change. Typically, only minor
the system. This mode of operation has been proven effective in treating greater mechanical or setpoint changes are required.
than seven times peak flow.
Stormflow Treatment Operation
TrueSND™ SYSTEM DESIGN In Stormflow treatment operation, solids are
stored in the outer channels, reducing solids
The concentric loop configuration of a typical Orbal® system operates in series. The
loading on clarifiers and preventing any loss of
unique design has become a trademark offered only by Evoqua with the channels
biological treatment during the storm event.
varying in size with the outer channel having 50% of the volume. Influent and return
activated sludge enter the outer channel which is operated under an oxygen deficit Process Knowledge
(anoxic) condition to promote simultaneous nitrification-denitrification. Envirex process engineers have been
By design, the aeration discs placed in the outer channel supply approximately 50% designing TrueSND biological treatment
of the system’s total oxygen requirement. The design ensures a constant oxygen systems for more than 20 years. Envirex
deficit condition throughout this channel with the DO set-point below zero. The has many Orbal plants meeting the most
oxygen deficit environment of the outer channel delivers an overall denitrification stringent effluent quality requirements.
performance rate of 80% without internal recycle. The majority of the system’s
nitrification takes place in the outer channel where the anoxic condition also drives
denitrification. This is the definition of a TrueSND biological treatment system.
The mixed liquor then flows hydraulically to the middle channel where DO conditions
swing depending on daily load variation. Finally the mixed liquor flows to the inner
channel where the DO is designed to operate at 2.0 mg/l. Final nitrification is
completed in the inner channel (or oxygenation zone) in surplus oxygen conditions.
The center island of the Orbal system houses the effluent structure that maintains
the water level throughout the channels of the basin. This structure can also serve
the purpose of a clarifier splitter box.
 ORBAL® SYSTEM REQUIRES LESS OXYGEN PROCESS FLEXIBILITY
Oxygen is introduced at multiple points in each channel The Orbal® system can be easily modified to meet a large
resulting in low intensity oxygen delivery and higher oxygen variation of effluent limits. The chart below explains the
transfer efficiency. An important part of the process is typical configurations of the Orbal® system. Typically only a
operating the outer channel at an oxygen deficit. This deficit simple process setpoint or mechanical change is needed to
creates an environment where specific nitrifying bacteria meet more stringent nitrogen or phosphorus effluent limits.
thrive. The chart below shows how the oxygen supply does
not match the demand in the first two channels which EFFLUENT QUALITY
corresponds to a low DO. In the inner channel the supply is
Typical effluent of an Orbal® system provides BOD <
greater than the demand and results in a positive DO.
10 mg/l and NH3-N < 1 mg/l. Effluent quality can be
TrueSND™ OXYGEN DEMAND VS. SUPPLY further improved with the configuration of the Orbal®
system outlined below.
100
Demand CONFIGURATION EFFLUENT (MG/L)
100

80 60% TN removal
2-channel Orbal®
TN<15
% OXYGEN DEMAND

60
80% TN removal
3-channel Orbal®
Supply Demand TN<10
40 50 50

Supply 90% TN removal

35
20 Supply
3-channel Orbal® w/ internal recycle TN<5
25 TP<1
Demand
15
90% TN removal
0 3-channel Orbal® w/ internal recycle
Outer Middle Inner TN<5
& Anaerobic zone
TP<1
CHANNEL
90% TN removal
3-channel Orbal® w/ internal recycle,
TN<5
Anaerobic zone & Post Anoxic zone
TP<0.5

Outer Channel

Middle Channel

Inner Channel

Orbal® system including its unique Concentric Loop design

 DESIGNS FOR TN LIMIT
WHAT DOES THE TrueSND SYSTEM PROVIDE?
Orbal® plants designed for TN removal will usually split the
TrueSND provides a highly efficient aeration oxygen delivery equally across all three channels. Adding
process. It is efficient in several parameters. an internal recycle will increase denitrification from 80% to
• Total tank volume. The Orbal® system counts above 90%. Additional considerations and design features are
the oxygen deficient zone as part of the total offered to plants where carbon to nitrogen ratios is reduced
aerobic SRT. Conventional systems with a due to primary clarification or industrial waste factors. For
separate anoxic zone will not account for enhanced TN removal, an internal recycle pump is introduced
the anoxic zone as aerobic SRT and require to achieve effluent total nitrogen levels less than 5.0mg/l.
additional tank volume. The Orbal® system
accounts for this volume because it is truly DESIGNS FOR TP LIMIT
being aerated. Approximately 80% of the air is Orbal® plants designed for biological phosphorus removal are
applied in such conditions. set for a low oxygen delivery in the outer channel. Typically,
• Energy. The SND in the Orbal® system 20% is applied to the outer channel with the remaining oxygen
typically results in a 35% reduction in power demand being satisfied in remaining channels. Envirex® Disc
over a conventional system due to oxygen Aerators provide sufficient mixing and oxygen delivery in the
recovery from the inherent denitrification outer channel without need for supplemental mixing.
process.
• Alkalinity. Approximately 50% of alkalinity ORBAL® SYSTEM INTERNAL RECYCLE PUMP DESIGN
consumed by the nitrification process is
Conventional plant designs rely entirely on an internal recycle
recovered. This helps control the pH level in the
pump for denitrification. The recycle pump for the Orbal®
system and eliminates the need to add alkalinity
system is a polishing step as SND takes place in the basin.
for typical municipal wastewater plants.

RECYCLE PUMP ADVANTAGE

100
The Orbal process achieves 80% denitrification without
C TrueSND internal recycle (circle A) where a conventional plant will have
90 40-50% (circle B). The internal recycle pump is a polishing
A
step for lower nitrogen limits. Adding a 2Q internal recycle
80 will increase the denitrification to 90% (circle C) in the Orbal
% DENITRIFICATION

Conventional D system, where as a 4Q recycle is typically used to achieve

80% denitrification (circle D) in a conventional plant.
70
The TrueSND biological treatment system eliminates the
60 need for a nitrate recycle pump compared to a conventional
activated sludge process saving capital and energy costs.
50

40
B

30
0 1 2 3 4 5

INTERNAL RECYCLE RATE, Q

STORMFLOW TREATMENT OPERATING MODE SMARTBNR™ CONTROLS
When the Orbal® system operates in Stormflow treatment The biological aeration system typically consumes the most
mode, the influent flow is directed from the outer channel power in a wastewater treatment plant. Evoqua process
to the inner channels for treatment. The return activated engineers work closely with electrical engineers to optimize
sludge from the clarifier continues to be pumped to the power consumption and process effluent quality for the
outer channel. Orbal® system. The SmartBNR controls utilize a touch screen
The Stormflow treatment mode represents an adjustment in operator interface with ORP and DO analyzers to continuously
solids inventory to the outer channel of the Orbal® system to monitor and adjust the aerator speed based upon the actual
prevent solids washout during peak hydraulic events. wastewater conditions and characteristics of the disc. The
controls also adjust for long-term variations or sudden surges
When flows return to normal, the influent flow is simply in demand by turning on/off individual assemblies.
returned to the outer channel and treatment proceeds routinely.
To meet strict ENR limits, the SmartBNR control system
This operating mode eliminates the need for an equalization optimizes TN and TP levels through ammonia probes and
basin. The conversion of normal to Stormflow mode can be phosphate analyzers. The control system has standard control
manually controlled or automatic through the SmartBNR™ options for Stormflow treatment mode of operation, nitrate
control system. recycle pumps, RAS pumps, SRT control, and chemical feed.
The SmartBNR control system from Evoqua provides remote
STORMFLOW TREATMENT MODE ADVANTAGE
access to the system control screens for process analysis
8000 and adjustments.
7000
Clarifier
Outer Channel AERATION POWER WITH TYPICAL
6000
DIURNAL FLOW PATTERN
CLARIFIER SOLIDS, LBS.

Middle Channel
ORBAL MLSS, mg/l

5000
100
90
4000
Manual Operation
3000 80 “Worst Case”

2000 70
POWER

Inner Channel
1000 60 Manual Operation
“Best Case”
0 50
0 50 100 150 200 250 300 SmartBNR
40
TIME, MINUTES
30
The chart above shows the activities of the Orbal and clarifier
20
biological solids during a Stormflow event. Influent is diverted 0 2 4 6 8 10 12 14 16 18 20 22 24

to the inner channel. The MLSS for the inner channel drops
TIME OF DAY
as the dilute influent displaces a portion of the solids to the
clarifier (blue line). The clarifier solids will initially increase, SmartBNR control systems save operating costs by only
providing the aeration power required to match the diurnal
but decrease (yellow line) as the RAS pumps transfer the load throughout the day.
solids to the outer channel. This action will increase the MLSS
in the outer and middle channel thus storing solids (red lines).
Activated sludge treatment will take place in the inner
channel as there are biological solids and oxygen in contact
with the influent. The RAS contacts the influent though the
displacement of liquid in the outer and middle channel and
flowing into the inner channel.
This operating mode eliminates the need for an equalization
basin. In many applications the use of this mode can also
reduce the size and/or number of clarifiers.
THE ENVIREX® DISC AERATOR ENABLES SND
REDUCED SPEED IMPROVES MIXING EFFICIENCY
The mechanical backbone of the Orbal® system is the unique
and patented aeration disc. It delivers a high oxygen transfer Mixing efficiency, defined as the number of gallons
rate and unmatched mixing efficiency. mixed per 1 hp to maintain a 1 fps channel velocity,
is an extremely important feature of the Orbal®
system. The disc is designed so that mixing efficiency
improves as speed is reduced. This characteristic is
beneficial to the Orbal® basin as it allows the process
to keep a DO deficit in the outer channel during
underloaded conditions, while still keeping a velocity
sufficient to keep solids in suspension. Independent
mixing devices are not needed to maintain anoxic
conditions in the outer channel.
The mixing efficiency of the aeration discs in an
Orbal® system basin is unmatched by any other
aerator device. As an example, an outer channel with
1 million gallons of volume requires only 10 hp of disc
aerators to maintain a 1 fps channel velocity. The high
The non-metallic Envirex® Disc Aerator provides a longer, mixing efficiency of Envirex aeration discs ensures
more cost-effective life when compared to galvanized or unparalled in biological process performance under all
painted carbon steel brush rotor designs. load conditions.

Aeration and mixing are provided by nodules on the face

of the disc, with oxygen delivery and energy consumption
varying with changes in speed and immersion depth.
The disc is split into two half sections and can be directly
attached to the aerator shaft at any location. The number
of discs allotted for each channel is a function of the oxygen
delivery requirements. In a typical 3-channel Orbal® system,
the outer disc aerator assembly spans the outer channel. The
inner aerator assembly spans the inner and middle channel.

Envirex® Disc Aerators provide superior

aeration and mixing without creating
unwanted aerosols and sprays.
FLOWSHEET SOLUTIONS: TECHNOLOGY
COMBINATIONS CREATE GREATER VALUE
Evoqua draws on its leading biological wastewater portfolio Evoqua Flowsheet Solutions are supported with a dedicated
and applications experts to support projects where multiple single technical point of contact who assures coordinated,
technologies can be combined into a high performing cost timely, and accurate project execution, along with a
effective solution. The Orbal® system, for example, can be comprehensive upfront evaluation of alternatives.
combined with:
• Tow-Bro® high performance clarifiers to achieve
stringent nutrient levels and handle peak flow rates Ready to put the technology, experience, and expertise
• A Forty-X™ Disc Filter for low TP applications of Evoqua to work?
• The innovative CoMag® Magnetite Ballasted Treatment
Learn more how the Orbal® system creates a
System to produce near MBR quality effluent in a small
simultaneous nitrification - denitrification environment
footprint
and addresses nutrient and Stormflow issues.
• TIW™ Control System Solutions that deliver seamless
controls across technologies without costly redundancy Connect with an expert at www.evoqua.com/orbal.

Flowsheet Solutions from Evoqua provide expertise and project support across technologies.
Influent Orbal® Multichannel Oxidation Ditch

Secondary Effluent

TowBro® Clarifier with

FEDWA Baffle System
SmartBNR™ Control
Patented Envirex®
System
Disc Aerator

Operator
Interface
Computers

To Solids Handling
RAS

WAS

2607 N Grandview Blvd, Suite 130, Waukesha, WI 53188

+1 (800) 524-6324 (toll-free) +1 (262) 547-0141 (toll) www.evoqua.com/orbal

CoMag, Envirex, Forty-X, Orbal, SmartBNR, TIW, Tow-Bro, TrueSND and the “Concentric Loop” configuration are trademarks of Evoqua
Water Technologies, its subsidiaries or affiliates in some countries.

All information presented herein is believed reliable and in accordance with accepted engineering practices. Evoqua makes no
warranties as to the completeness of this information. Users are responsible for evaluating individual product suitability for specific
applications. Evoqua assumes no liability whatsoever for any special, indirect or consequential damages arising from the sale, resale or
misuse of its products.

© 2015 Evoqua Water Technologies LLC Subject to change without notice BC-ORBAL-BR-0415