ClearFox® FBBR
Fixed Bed Biofilm Reactor
Advanced Biological Treatment Process
- Exceptional Process Stability
- Continuous Automated Operation
- Certified High Performance
- 99% Cleaning Efficiency
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Description
The ClearFox® FBBR (Fixed Bed Biofilm Reactor) is a high rate biological wastewater treatment process. It operates using the submerged fixed bed process in which microorganisms colonize fixed carrier materials and efficiently break down pollutants such as organic compounds and nitrogen-based substances. The exceptional process stability makes it suitable for a broad range of industrial and municipal wastewater applications, guaranteeing consistently high cleaning efficiency even under challenging conditions. Our modular design allows for flexible configuration in series or parallel, enabling treatment capacities from 10 m³/day up to 5,000 m³/day.
How It Works
- Wastewater enters the containerized system (1)
- Oxygen is supplied via diffused aeration (2)
- Fixed bed cascades supports biofilm growth for high rate biological treatment (3)
The reactor chambers are arranged in a cascaded layout within the container and equipped with carrier materials offering different specific surface areas (100 m²/m³ – 200 m²/m³). The wastewater flows step by step through biological reactors, where adapted microbial communities develop depending on the pollutant load. Biological degradation generally follows an exponentially flattening curve. Because of the cascaded design with increasing carrier surface area, the degradation rate in our ClearFox® FBBR remains consistently within the optimal range. To supply oxygen to the biomass, an aeration system is installed beneath the carrier materials, creating ideal conditions for microbial growth and efficient biological degradation by the biofilm.
Advantages
- Robust Technology
One of the key advantages of the ClearFox® fixed bed technology lies in its exceptional process stability. Unlike conventional biological treatment systems, the bio-film in the submerged fixed bed reactor adapts automatically to varying loads. The ClearFox® FBBR continues to operate reliably even with fluctuations in influent values, grease leaks or interruptions in the oxygen supply.
This makes the ClearFox® system suitable for all types of wastewater applications – from municipal treatment to the most challenging industrial wastewater.
- Low Operating Costs
The efficient operation of ClearFox® systems does not require specialized personnel. No weekly adjustments, no complex measurement or control technology: The fixed bed reactor ensures biological stability autonomously. The system is designed for minimal maintenance effort.
Combined with low energy consumption, this results in low and predictable operating costs (OPEX) throughout the entire lifetime of the system.
- Fast Turnaround
Our ClearFox® FBBR containers are manufactured at our production site in Germany according to the plug & play principle: All components such as connections and pipelines are pre-installed, ensuring minimal installation effort on-site. Thanks to the modular design, the systems can be easily expanded or relocated to another site at any time.
This significantly reduces risk for operators and investors – fast availability, short installation times, and flexible scalability provide reliable implementation and planning security.
- Compact Design
Based on more than 20 years of experience with all common wastewater treatment processes, we have deliberately specialized in the modified fixed bed process. It combines a compact design with consistently high treatment performance. Only MBR systems can achieve higher removal rates per footprint.
However, our experience has shown: High energy demand, membrane replacement costs, and complex operation often prevent stable long-term performance in MBR systems, making them unsuitable for most applications.
- Certified Performance
ClearFox® is the first and only company to subject its fixed bed container system to a 52-week long-term test at an independent test institute (PIA). During the test, our 20-foot fixed bed container reliably removed 100 kg of COD and 40 kg of BOD per day.
In real industrial applications with highly polluted wastewater, our container systems have already achieved up to 130 kg of COD removal per day.
Videos
We design custom solutions tailored to each project and site requirements. The 20 ft and 40 ft. ClearFox® FBBR (Fixed Bed Biofilm Reactor) include the biological treatment stage without primary and secondary clarification. We also offer complete standalone sewage treatment plants with primary and secondary clarification under ClearFox® Packaged FBBR Plants.
Specifications FBBR Container (above ground)
| Module type | 20ft. FBBR |
|---|---|
| PE | 667 |
| COD removal rate [kg/d] | 100 |
| BOD removal rate [kg/d] | 40 |
| NH4-N removal rate [kg/d] | 8 |
| Feedrate [m³/d] | 100 |
| Feedrate [m³/h] | 5 |
| Measures (l/w/h) in m | 6,1 / 2,5 / 2,8 |
| Control unit | Inside |
| Weight (transport/operation) [to] | 7,5 / 35 |
| Power consumption [kWh/d] | 55,8 |
| Module type | 40ft. FBBR |
|---|---|
| PE | 1333 |
| COD removal rate [kg/d] | 200 |
| BOD removal rate [kg/d] | 80 |
| NH4-N removal rate [kg/d] | 16 |
| Feedrate [m³/d] | 200 |
| Feedrate [m³/h] | 10 |
| Measures (l/w/h) in m | 12,2 / 2,5 / 2,8 |
| Control unit | Inside |
| Weight (transport/operation) [to] | 12 / 58 |
| Power consumption [kWh/d] | 100,8 |
Specifications FBBR AP Tanks (below ground or reinforced with steel above ground)
| Module type | FBBR2250 |
|---|---|
| Tank | 2250 L Tank |
| Carbon reduction | |
| PE | 74 |
| Max. feedrate [m³/d] | 11,1 |
| Carbon reduction (COD) [kg/d] | 7,4 |
| Carbon reduction and nitrification | |
| PE | 31 |
| Max. feedrate [m³/d] | 4,6 |
| Carbon reduction (COD) [kg/d] | 3,1 |
| Nitrification (NH4-N) [kg/d] | 0,31 |
| Weight transport/ operation [kg] | 200 / 2300 |
| Inlet/ Outlet connection | DN 100 |
| Measures (l,w,h) in cm | 154/ 122/ 171 |
| Power consumption [kWh/d] | 1,71 |
| Module type | FBBR3500 |
|---|---|
| Tank | 3500 L Tank |
| Carbon reduction | |
| PE | 122 |
| Max. feedrate [m³/d] | 18,3 |
| Carbon reduction (COD) [kg/d] | 12,2 |
| Carbon reduction and nitrification | |
| PE | 51 |
| Max. feedrate [m³/d] | 7,6 |
| Carbon reduction (COD) [kg/d] | 5,1 |
| Nitrification (NH4-N) [kg/d] | 0,51 |
| Weight transport/ operation [kg] | 250 / 3550 |
| Inlet/ Outlet connection | DN 100 |
| Measures (l,w,h) in cm | 243/ 122/ 171 |
| Power consumption [kWh/d] | 4,05 |
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Reference Projects
FAQs
1. What is the ClearFox® Fixed Bed Biological Reactor (FBBR)?
The ClearFox® FBBR is a high-rate biological wastewater treatment process utilizing a modified “fixed bed” system. It is designed for both standalone biological treatment of municipal wastewaters and high-rate treatment of pretreated industrial wastewaters. The system can handle flow rates ranging from 10 to 5,000 m³/day by configuring modules in series or parallel.
2. How does the ClearFox® FBBR differ from traditional activated sludge processes?
Unlike typical activated sludge processes, the ClearFox® FBBR is more robust and capable of handling higher pollutant concentrations. It produces less sludge and has a more compact footprint due to the dense biomass on its fixed bed media.
3. What are the advantages of using the ClearFox® FBBR system?
- High Efficiency: Achieves high-rate pollutant removal in a compact footprint.
- Versatility: Suitable for both industrial and municipal wastewater treatment.
- Flexible Installation: Can be installed above or below ground.
- Cost-Effective: Features low capital (CAPEX) and operational expenditures (OPEX).
- Scalability: Easily expandable with additional modules.
- User-Friendly: Operates automatically with minimal training required.
- Rapid Deployment: Allows for quick installation and startup.
- Durability: All components are corrosion-resistant.
- Environmental Benefits: No chemicals are required, and no odors are produced.
- Effluent Quality: Produces final effluent suitable for reuse.
4. Is the ClearFox® FBBR system suitable for fluctuating wastewater flows?
Yes, the system is designed to handle fluctuating wastewater flows, including underload and overload conditions, without compromising performance.
5. Can the ClearFox® FBBR be used for both municipal and industrial wastewater treatment?
Absolutely. The ClearFox® FBBR is versatile and suitable for treating both municipal and industrial wastewater streams.
6. What maintenance requirements does the ClearFox® FBBR have?
The system is designed for minimal maintenance, operating automatically and requiring only simple control measures. This self-regulating feature is due to the submerged, permanently installed fixed growth media.
7. Does the ClearFox® FBBR system require chemical additives?
No, the system operates efficiently without the need for chemical additives, making it environmentally friendly.
8. How does the ClearFox® FBBR compare to MBBR and MBR technologies?
The ClearFox® FBBR is more robust than Moving Bed Biofilm Reactor (MBBR) and Membrane Bioreactor (MBR) processes. It handles higher pollutant concentrations and produces less sludge, resulting in lower operational costs.
9. Is the ClearFox® FBBR system certified?
Yes, the ClearFox® FBBR technology has been independently certified by PIA GmbH, a leading notified test facility for wastewater treatment.
10. What are the installation options for the ClearFox® FBBR system?
The system offers flexible installation options, suitable for both above-ground and below-ground setups, depending on site requirements. For more detailed information, you can refer to the ClearFox® FBBR brochures and data sheets below.
