Hebbal, Bengaluru
BNR Activated Sludge Process
Lump Sum Turnkey (LSTK)
100 MLD (+ 1.0 Mwe)
The Hebbal project for the BWSSB is a model of resource recovery in an urban setting. Processing 100 MLD of municipal sewage, the facility utilizes an advanced BNR process to ensure that the treated effluent is of high enough quality for agricultural irrigation.
Simultaneously, the plant leverages its organic waste to generate 1.0 MWe of green electricity, significantly reducing the facility’s reliance on the local power grid.
The objective was to create a dual-purpose infrastructure capable of alleviating Bengaluru’s water stress.
By treating wastewater to irrigation standards, the project supports the local agricultural belt, while the integrated biogas-to-power unit captures methane to drive a 1.0 MWe generator, turning a traditional cost center into a self-sustaining asset.
Implementing Biological Nutrient Removal (BNR) at a 100 MLD scale requires precise control over anaerobic, anoxic, and oxic zones.
The challenge involved optimizing these zones to remove nitrogen and phosphorus to safe levels for agricultural reuse while maintaining a high-yield biogas production cycle for the power generation unit.
The solution utilized an Advanced Activated Sludge Process integrated with a BNR configuration for superior effluent polishing.
To maximize energy recovery, the sludge is processed in anaerobic digesters to produce biogas, which is then scrubbed and fed into a 1.0 MWe Gas Engine.
This ensures a high-quality water output for irrigation and a renewable energy stream that powers a significant portion of the plant’s mechanical operations.
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