Customer: Huge landfill company in western Germany
Year: 2018/2019

Leachate from landfill

is wastewater, which is accumulated on the bottom of a compartment or a landfill. The composition and the hydraulic flow of this water depends on the type of waste which was stored, the annual and momentary precipitation and last but not least the age of the landfill.

Older landfills drain less biodegradable organic matter (BOD/COD relation to zero). Typically pollutions can be high nitrogen concentrations (NH4, N02, N03, various hydrocarbons – often organ halogens, chlorides, sulphates, different heavy metals
(i.e. Zn, Cu, Ni, Cr, Cd, Hg, Pb and more)

The water usually shows less turbidly, it has a less brown color and mostly a penetrating smell can be detected. So in short: it is highly polluted, it has fluctuating hydraulics and it requires various process technologies to meet the effluent requirements, according to the local regulations.


AVE – Alte Schanze, Germany is a landfill with production residues (i.e electroplating, fuel ashes), urban, oily and construction waste. Beside has an older area with different harmful residues, arised back to the year 1979 restriction and law.
Out of the landfill body are draining around 200.000 m3 leachate per year, which are collected and they need to be treated. The old wastewater system was not able to reach the effluent requirement. A new system was called for tenders.

After a selection period finally PPU was submitted for engineering, procurement and construction of the main part of the new waste water system.

Why PPU was selected? What are the advantages for the client:

We could offer out of one hand our standard ClearFox containerized treatment modules by looking back on more than 25 years experience of industrial wastewater.

The process technology suggested from PPU was validated by external consulting offices. All modules have been before approved externally, the precasted modules had finally the best price/quality relation in comparison to our competitors all over Europe.

Requirements for the sewage treatment plan

Input Parameter

Effluent Parameter

Finally the selected process technology is:

Precipitation, Flocculation, Dissolved Air Flotation, ozone treatment, Denitrification, Nitrification, Fuzzy Filtration, Activated Carbon Adsorption, the sludge goes to an existing gravity thickener and it is pressed in certain intervals.

Lifetime pictures of executed system and function

Precipitation, flocculation lines, saturation lines
Chemical treatment for split table matter,
pH adjustment, buffering and nutrients adjustment


Twin Dissolved Air Flotation – DAF

Floating of oil, floatable matter,
Fine separation of TSS and splitted flocculated material
Sludge discharge into a sludge funnel and pumped to thickening

Ozone treatment

Cracking into degradable organics, reducing COD, providing carbon source for denitrification

denitrification of nitrate, control of nitrite hyperboloid mixer system optional methanol dosing, recirculation BOD from Ozon Circle

Control cabinet for connected power 100 kilowatt, touch panels, SCADA System to main unit, Frequency controllers, flow controls, etc

side channel blower battery with splitter
Lamella clarifiers, sludge return and side channel blower battery with splitter
FBR Fixed Bed Reactor
Nitrification reactors, cascades FBR-reactors, the Sea container are outside the building, they are weather protected and insulated

5 independent reactors, splitter, manual change between gravity flow for nitrification- denitrifcation as per demand

5 independent reactors, splitter, manual change between gravity flow for nitrification- denitrifcation as per demand

The wastewater can be led through several process steps. These can be like in the pictures above. The process is fully automatic and the daily flowrate, which is depending on the rainfall can be adjusted manually. All steps can be bypassed, and the flow can be reversed by manually switching valves (i.e. if more nitrate in raw water, then first denitrification, then nitrification)
The following effluents between the treatment steps are achieved.

Range concentrations [mg/l after step beforeCODBSB5NgesNH4-NNO3-NPAFSChloridheavy Metals
prebiological treatment4000100400200200100
Clearfox Flotation≤ 800-600≤ 10020070130≤ 51500
Dosierung P-Quelle700100200701305-105  
Ozone70035020070130≥ 4≤ 5
Dose C-Quelle

Dose  P-Quelle



C/N Reaktors + lamella250507010602 20
limit4007010 3201500seperate schedule

The system is started hydraulically without any troubles since November 2018. The final acceptance procedure was end of March 2019. Lead time was – due to containerized type- around 12 weeks.

This is a simplified flow chart (P&I) which shows main part of the treatment system.

For further information please contact PPU technical team