Double Your WWTP Capacity Without New Tanks: The Power of PU Sponge Bio-Media

Bywatertech

Category: Technology & Innovation / WWTP Retrofit Reading Time: 4 Minutes

The Challenge: Growing Load, Limited Space

For many wastewater treatment plants (WWTPs), the challenge is universal: stricter effluent standards (especially for Nitrogen removal) and increasing influent loads, but zero space to expand the physical footprint.

Traditional Activated Sludge (CAS) systems or standard plastic carriers often hit a performance ceiling. You need a carrier that holds more biomass in the same volume without clogging.

Enter the HNS Watertech Polyurethane (PU) Sponge Bio-Carrier – the next-generation solution for high-concentration biological treatment in fluidized bed processes.

Why PU Sponge? The “Inside” Story

Unlike standard HDPE media which relies on external surface area, our PU Sponge Media utilizes a reticulated, open-pore structure. This allows bacteria to grow not just on the surface, but deep inside the cube.

1. Unmatched Surface Area (Outperforming the Standard)

While standard HDPE media typically offers 500–800 m²/m³, and even premium German sponge competitors claim ~1,000 m²/m³, HNS Watertech’s PU Sponge boasts an effective surface area of over 3,000 m²/m³.

  • The Result: A denser biomass concentration means you can treat significantly higher pollution loads with a smaller reactor volume.

2. Significant Sludge Reduction (Cost Saving)

One of the hidden benefits of our porous structure is the long Sludge Retention Time (SRT). The biomass stays protected inside the sponge for longer periods, promoting endogenous respiration.

  • The Benefit: This process naturally degrades old biomass, leading to a 30-50% reduction in excess sludge production compared to conventional systems. This directly lowers your sludge dewatering and disposal costs.

3. Simultaneous Nitrification & Denitrification (SND)

This is the game-changer for Nitrogen removal.

  • Outer Layer: High dissolved oxygen (DO) supports Nitrification.
  • Inner Core: Low DO (anoxic zone) supports Denitrification.
  • Benefit: Achieves Total Nitrogen (TN) removal in a single tank, simplifying your process design.

4. Resistant to Abrasion & Clogging

Engineered for the rigorous mixing of Fluidized Bed Processes, HNS Virgin PU Sponge is highly resistant to mechanical abrasion. The material flows freely with water and air bubbles, creating a self-cleaning effect that prevents clogging—even after years of operation.

Technical Specifications: HNS Watertech vs. Standard Media

FeatureHNS PU Sponge Media (Virgin)Standard HDPE Media
Material100% Virgin PolyurethaneRecycled or Virgin HDPE
Specific Surface Area> 3,000 m²/m³~800 m²/m³
Sludge ProductionLow (Extended SRT)High
Bio-Film TypeAerobic & Anoxic (SND)Mostly Aerobic
Wear ResistanceHigh (Elastic & Durable)Medium (Rigid Plastic)

Pro Tip: Not all sponges are created equal. HNS uses a specific 25-PPI (Pores Per Inch) density to ensure optimal water flow and prevent clogging, solving the common issues found in cheaper foam products.

Ideal Applications

  1. WWTP Upgrades (Retrofit): Increase capacity by 50-100% in existing aeration tanks.
  2. IFAS Systems: Integrated Fixed-film Activated Sludge processes in concrete or steel tanks.
  3. Industrial Wastewater: High-strength organic wastewater (Paper, Textile, Food & Bev).
  4. Anaerobic Treatment: Excellent carrier for anaerobic bacteria due to high porosity.

The HNS Guarantee: Pure White, Pure Performance

We know that durability is the #1 concern with sponge media. That is why HNS Watertech produces only White, Virgin PU Media.

  • No Recycled Scrap: Ensures the sponge won’t crumble or degrade after 1-2 years.
  • Long Lifespan: Designed for 10+ years of operational life.
  • Custom Sizes: Available in 20mm, 30mm, 50mm cubes, or large sheets (1x2m).

Ready to Upgrade?

Don’t let limited space limit your plant’s performance. Switch to the high-efficiency power of PU Sponge.

Contact our technical team today for a free calculation of your required media volume.

📧 Email: [email protected] 🌐 Website: www.hnswatertech.com

PU Sponge media
HNS PU Sponge Media (Virgin)

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