A dyehouse discharges in batches: one caustic desize, one hot dye bath, one rinse. The biological stage sees a load that swings by a factor rather than a percentage, and the media has to survive that swing without losing its bed.
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| Batch, not continuous | Load arrives in slugs as dye lots are dropped. Equalisation is the first design decision, and it is more important than the media |
| Colour and refractory COD | A biological stage removes the biodegradable fraction; the colour and the refractory fraction usually need chemical or advanced treatment alongside it. No media solves colour on its own |
| Temperature and pH swings | Hot, alkaline dye baths arrive intermittently. Published carrier working range is 5–60 °C, but the swing matters more than the absolute value |
| Salts | Dyeing uses salt. It does not attack HDPE, but it changes the biology and the sludge behaviour |
Moving bed biological stage. Carriers give a large protected surface in the tank volume the site can spare, do not need backwashing, and recover quickly after a toxic slug passes through because the biofilm regrows from the protected volume. Published figures for our K-series: over 800–1000 m²/m³ specific surface, 85–90 % void, 15–67 % fill band, 2000–15000 g/m³·d organic oxidation.
Settling after chemical treatment. Where coagulant or lime is dosed for colour, the resulting floc settles in lamella media rather than in a large clarifier - the reason textile plants in land-constrained industrial estates use settling media at all. Published: Φ25–90 mm cells at 62–236 m²/m³, 93–97 % porosity, 3–5 t/m²·h loading, 4–5 m stack at 60°.
Aeration. A moving bed needs oxygen. Disc aerators and ABS air piping are specified with the carriers, not after them: the fill fraction and the aeration capacity have to be decided together.
We will not quote a colour removal figure for media, because colour removal in a dyehouse is a chemistry and oxidation question, not a surface area question. What media delivers is the biological capacity to take out the biodegradable load and the settlement capacity to remove the floc that follows chemical dosing. If a supplier promises colour removal from carriers alone, the plant will be disappointed at commissioning.
Products: MBBR carriers · settling media · inclined plate media · disc aerators · more industries: all applications.
No. Carriers remove the biodegradable load; colour and refractory COD normally need chemical or advanced oxidation alongside the biological stage. What the carriers do is keep the biological capacity stable through batch swings, which makes the downstream colour step predictable.
Equalise first. A buffer tank that flattens the batch slugs does more for the biological stage than any media change. Size the media against the equalised load, not the peak drop.
A coarse to mid grade from the K-series, chosen with the fill fraction on the upper side of the published 15-67 percent band to absorb the load swings, and matched to the aeration capacity available.
It can replace the area of it: published capacity is 3-5 times a horizontal-flow basin in the same footprint. Whether it replaces the clarifier itself depends on the sludge handling and the weir, which the drawings will show.
We specify the equalisation, the biological stage and the settling stage as one train, and say plainly what media cannot do.
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