Molecular Chemical Grinder Improves Digestion in Sludge

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Courtesy of In-Pipe Technology Company, Inc.

Municipal wastewater treatment plants (WWTPs) can reduce the costs and liabilities of sludge handling and disposal and increase their organic solids conversion rate with the Advanced Fluidized Composting (AFC) Process or the Advanced Fluidized Co-Digeson & Co-Generaon (AFC2) Process from BioConversion Soluons, LLC (BCS).

The conventional sludge treatment techniques of aerobic and anaerobic digestion leave a considerable amount of organic sludge that requires hauling and appropriate disposal. BioConversion Solutions in conjunction with In-Pipe Technology Company, Inc. offer the AFC & AFC2 processes, patented techniques to reliably reduce waste sludge from aerobic and anaerobic digester systems (AFC & AFC2) while increasing gas production from anaerobic systems (AFC2).

Conventional anaerobic digestion facilities that produce methane typically have a biosolids to energy conversion rate of 40%-55%, leaving a considerable amount of potential biogas production in the sludge that gets hauled away and disposed of. A complete AFC2 implementation can increase the solids conversion rate up to 80%-90%, resulting in up to 100% increase in biogas production and a very large reduction (up to 80%) in residual sludge disposal challenges and costs.

AFC Aerobic Thermophilic Process
AFC is a unique process technology for treatıng highstrength organic waste streams and residual biosolids from conventıonal wastewater treatment processes. AFC enables a much higher degree of solids destructıon, generaıng little or no residual sludge. The AFC process works well with conventıonal and thermophilic aerobic or mesophilic anaerobic biological treatment to also increase methane productıon by incorporating the AFC2 process. With fullscale systems operaıng in Europe, Asia and United States, the AFC process is a proven technology that is currently treatıng a wide range of high strength organic waste and sludge worldwide.

AFC & AFC2 Process with MCG Technology
BioConversion Solutıons’ next generaıon of the AFC technology uılizes molecular chemical grinding (MCG) units to condition the sludge by reducing large solids to smaller molecular weight compounds using intensive mixing energy. This process dramaıcally increases the digestibility of biosolids, resulting in greater volatile solids destruction and less residual biosolids for disposal. MCG units enable the same sludge conditioning as the AFC chemical side stream process without chemical use or chemical storage and with a smaller footprint. The MCG technology has been deployed in a variety of applications over the past 20 years and can be applied to both aerobic and anaerobic digester systems.

The AFC process is a proprietary side stream treatment that can be easily retrofi9ed into exiting equipment or designed into new construction. This treatment increases the solids deconstruct rate of aerobic and anaerobic digesters by increasing the bio-availability of the sludge. The AFC2 system has the added feature of increasing gas producon from anaerobic systems. The AFC and AFC2 processes have been implemented in numerous plants worldwide to completely eliminate sludge.


  • Up to 90% reduction in residual sludge production
  • Minimizes or eliminates sludge disposal costs (solids destruction performance varies with process application)
  • Increase gas production from anaerobic digester process by 100%+ (AFC2 process)
  • AFC process adds thermal energy: more stable digester operation through improved temperature control.
  • Excellent system stability: minimal process oversight required
  • Existing treatment systems can be easily retrofi9ed with AFC
  • Short payback from sludge hauling savings and digester gas power generation

In-Pipe Technology: Operaıng Savings & Efficiency
In-Pipe increases operaıng eefficiency by reducing influent organic loading and the costs associated with sludge handling and disposal, expensive chemicals, and energy usage.

The reduced loading at the plant, coupled with a more efficient microcosm reduces aeraıon requirements and provides significant energy savings.

Water Quality
In-Pipe Technology improves water quality for discharge or reuse by reducing influent organic loading and euent pollutant levels. In-Pipe has helped compliant plants funcıon more efficiently and has helped non-compliant plants achieve their targets.

Inside a WWTP
By initiating productive microbiological acıvity in the collection system, In-Pipe digests organic maıer as it moves through the enıre system improving the influent bioavailability. In-Pipe can structure treatment design to address industrial inputs into the collecıon system. It works with both conventional treatment processes and new designs using membrane bioreactors.

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