Biorock ECOROCK-5000 Manuel utilisateur

PAGE 1 / 52 Installation and User guide –ECOROCK-5000 & BIOROCK Multirock Systems –10-10-2017

INSTALLATION AND USER GUIDE

ECOROCK-5000

BIOROCK® Multirock systems

BIOROCK Multiple Installations

PAGE 2 / 52 Installation and User guide –ECOROCK-5000 & BIOROCK Multirock Systems –10-10-2017

PAGE 3 / 52 Installation and User guide –ECOROCK-5000 & BIOROCK Multirock Systems –10-10-2017

TABLE OF CONTENTS

A. INSTALLATION GUIDE .............................4

B. USER GUIDE...........................................27

C. APPENDICES ..........................................39

PAGE 4 / 52 Installation and User guide –ECOROCK-5000 & BIOROCK Multirock Systems –10-10-2017

Dear Customer,

Congratulations on your purchase of this BIOROCK® Domestic Sewage Treatment Plant. Your new

BIOROCK will guarantee years of trouble-free operation, peace of mind and protection for the

environment.

We highly recommend that you familiarize yourself with this guide for the installation, commissioning

and maintenance of your new BIOROCK system.

The instructions for the maintenance and visual checks of the system will ensure that you have a

reliable and long-lasting sewage treatment plant.

Please do not hesitate to contact your BIOROCK distributor for any queries or further assistance.

Thank you for choosing BIOROCK.

The installation and commissioning of your BIOROCK system should be carried out by a BIOROCK trained

and approved installer. Your installer will be able to offer you a maintenance contract. The BIOROCK

Warranty is only valid if the required maintenance is carried out by a BIOROCK trained and approved

installer.

Should you not wish to take out a maintenance contract, make sure you have your sewage treatment

plant inspected and maintained on a regular basis by an industry trained, competent wastewater

professional.

BIOROCK S.à.r.l.

4-5 ZAE le Triangle Vert

L-5691 Ellange

Luxemburg

E-mail: info@biorock.com

Telephone: +352-26-17 66 33

Distributor’s name:

Contact person:

Address:

E-mail:

Telephone:

READ CAREFULLY

A. INSTALLATION GUIDE

PAGE 5 / 52 Installation and User guide –ECOROCK-5000 & BIOROCK Multirock Systems –10-10-2017

A. INSTALLATION GUIDE

ECOROCK-5000

BIOROCK Multirock systems

BIOROCK Multiple Installations

A. INSTALLATION GUIDE –TABLE OF CONTENTS

PAGE 6 / 52 Installation and User guide –ECOROCK-5000 & BIOROCK Multirock Systems –10-10-2017

TABLE OF CONTENTS

1. THE BIOROCK SEWAGE TREATMENT SYSTEM ....................................................... 7

1.1. General points ...............................................................................................................7

1.2. Sizing …...………………………………………………………………………………………………………….….……...............7

1.3. Precautions ....................................................................................................................8

1.4. Identification ..................................................................................................................9

1.5. Handling and transport of the tanks ..............................................................................9

2. OPERATING PRINCIPLE OF AN ECOROCK SEWAGE TREATMENT PLANT ................10

2.1. The Primary Tank ........................................................................................................ 10

2.1.1 Ventilation of the Primary Tank .................................................................. 10

2.1.2 Performance of the Primary Tanks (PT)........................................................ 10

2.2. The BIOROCK Treatment Unit (Bioreactor) –ECOROCK-5000 .................................... 12

2.3. ECOROCK-5000 Treatment Unit : Technical ................................................................ 12

3. INSTALLATION LAYOUTS.....................................................................................13

3.1 Installation layout n°1.: Gravity discharge (non-electric)........................................... 13

3.2 Installation layout n°2.: Pumped discharge (pump after PT) ......................................13

3.3 Installation layout n°3.: Pumped discharge (pump after ECOROCK unit) ...................13

4. INSTALLATION OF THE TANKS ............................................................................14

4.1 Installation principle.................................................................................................... 14

4.1.1 Before the installation of the complete system............................................ 15

4.1.2 Installation of the Primary Tank .................................................................. 15

4.1.3 Installation of the ECOROCK treatment unit ............................................... 16

4.2 Installation in dry ground conditions .......................................................................... 16

4.2.1 Installation and digging in dry ground conditions........................................ 16

4.2.2 Installation of the Tanks in dry ground conditions....................................... 16

4.2.3 Backfilling in dry ground conditions ............................................................. 17

4.3 Installation in wet ground conditions.......................................................................... 17

4.4 Installation in “difficult” areas and sites...................................................................... 19

4.4.1 Installation in difficult areas and sites ......................................................... 19

4.4.2 Installation in difficult ground conditions .................................................... 19

4.4.3 Backfilling in difficult ground conditions...................................................... 19

4.5 Installations under roads, courtyards or storage areas............................................... 20

4.6 Other specific cases ..................................................................................................... 20

4.6.1 Incline too steep (> 5%) ................................................................................ 20

5. VENTILATION AND WATER DISTRIBUTION ..........................................................21

5.1 Ventilation of the Primary Tank................................................................................... 21

5.2 Ventilation of the ECOROCK-5000 treatment unit...................................................... 22

5.3 Water distribution pipe ............................................................................................... 22

5.4 BIOROCK® media ......................................................................................................... 23

5.5 Securing the lids........................................................................................................... 23

6. STOPPING AND RESTARTING THE SYSTEM ..........................................................24

7. CONFORMITY AND WORK COMPLETION ............................................................24

8. RECOMMENDATIONS OF USE AND MAINTENANCE ............................................24

9. COMPLIANCE WITH REGULATIONS AND STANDARDS..........................................24

10. WARRANTY ......................................................................................................25

A. INSTALLATION GUIDE 1. THE ECOROCK-5000 TREATMENT PLANT

PAGE 7 / 52 Installation and User guide –ECOROCK-5000 & BIOROCK Multirock Systems –10-10-2017

1. THE BIOROCK SEWAGE TREATMENT SYSTEM

1.1 GENERAL POINTS

The ECOROCK-5000 unit from BIOROCK is a compact non-electric Sewage Treatment Plant. The

treatment relies on the revolutionary BIOROCK biological purification process. The ECOROCK-5000

sewage treatment unit is exclusively designed for domestic waste water purification.

The BIOROCK plant consists of a Primary Tank and an ECOROCK-5000 Bioreactor. Both parts (Primary

Tank and Bioreactor) must be independently ventilated.

A small pump can be installed in a pump shaft downstream of the system to lift the treated water and

discharge to a higher level if needed.

BIOROCK recommends the installation of an effluent sampling at the outlet of the treatment unit.

The ECOROCK-5000 treatment unit can be installed after a non-BIOROCK Primary Tank, provided that

this tank is properly sized, equipped with an efficient effluent filter and properly, independently

vented.

1.2 SIZING

The ECOROCK-5000 unit has a capacity of 30 P.E. (Person Equivalent). The capacity of the individual

ECOROCK-5000 unit can be increased if the required final effluent quality is of a lower standard than

the results, achieved during the EN-12566-3 Performance test.

The ECOROCK-5000 units can be installed in parallel for larger capacities (BIOROCK Multirock Systems).

When the ECOROCK-5000 units are installed in parallel, we recommend the use of a Flow Management

System between the Primary Tank and the Treatment Units. The BIOROCK Flow Control Chamber (FCC)

and Splitterbox (SB) are an option.

The FCC acts as a ‘header tank’ to provide a controlled surge flow to the SB and guarantees equal flow

to each of the BIOROCK units installed in parallel.

The standard BIOROCK Flow Control Chamber and BIOROCK Splitterbox are suited for a maximum of

3x ECOROCK-5000 units; for more ECOROCK-5000 units in parallel, another Flow Control Chamber and

Splitterbox with a larger capacity should be used.

VOLUME

PRIMARY

TANK

FLOW CONTROL

CHAMBER

Maximum

ORGANIC LOAD

Maximum

HYDRAULIC LOAD

Up to 30 PE

ECOROCK-5000

BIOROCK

recommends a

minimum

volume of 3x the

daily water

production

2,25 Kg BOD5/day

4.500 L./ day

Up to 60 PE

ECOROCK-5000

YES

4,50 Kg BOD5/day

9.000 L./ day

Up to 90 PE

ECOROCK-5000

YES

6,75 Kg BOD5/day

13.500 L./ day

Up to 120 PE

ECOROCK-5000

YES

9,00 Kg BOD5/day

18.000 L./ day

Etc.

YES

11,25 Kg BOD5/day

22.500 L./ day

A. INSTALLATION GUIDE 1. THE ECOROCK-5000 TREATMENT PLANT

PAGE 8 / 52 Installation and User guide –ECOROCK-5000 & BIOROCK Multirock Systems –10-10-2017

1.3 PRECAUTIONS

Please note that BIOROCK shall not be responsible for any installation design parameters and

groundworks at any case. We recommend to involve a civil engineer or a specialized design office in

the design of the system installation if necessary and to follow best practices of the industry.

This is especially true for the Multirock installations; considering the larger volumes of wastewater

to be treated, a proper dispatching through all Treatment Units is essential for efficiency of the

system.

It is the installer’s responsibility to ensure equal distribution of the wastewater by testing the Flow

Management System prior to leaving site. The installer should ensure any necessary supplementary

setting on the BIOROCK or non-BIOROCK Flow management System if necessary.

Important precautions for the proper use of the BIOROCK system: Only domestic sewage should enter

the system; no rainwater is allowed.

To ensure the good working order of the BIOROCK system, the use of automatic toilet cleaners, electric

waste-disposal systems and pumps equipped with blades are not to be used.

If there is a professional kitchen on site, an efficient and properly sized grease trap should be installed.

The grease trap should be installed before the primary tank.

Do not dispose of the following items to the BIOROCK system:

Kitchen or motor oils, fats, wax, resin, paint, solvents, hydrocarbon-based products (petrol, crude oil

etc.), any pesticide or antibacterial product, items of a toxic nature, boiler or air-conditioning

condensate, swimming pool backwash, rainwater, drainage water or ground-water.

An effective effluent filter should be installed in the outlet of the Primary Tank, before the water

goes on to the Bioreactor.

Pipework after the ECOROCK units, and especially after Multirock installations, should allow

sampling.

Special care should be taken with the aeration of the system. The aeration should be checked by the

installer using a smoke test once pipework and ventilation ducts have been connected and before

backfilling the system. The smoke test should be performed under normal representative conditions.

Each system should be vented independently and equipped with its own ventilator (wind driven or

electrical). The number of elbows used in the pipework should be limited as much as possible. 90o

elbows should not be used, 45oelbows should be used instead. The high air outlets should be installed

as close as possible to the low air inlets.

Achieving efficient ventilation is the responsibility of the installer as he is familiar with the

implementation, site and local conditions that may interfere in the system’s venting.

The Primary Tank should be aerated separately in accordance with the manufacturer's instructions.

A. INSTALLATION GUIDE 1. THE ECOROCK-5000 TREATMENT PLANT

PAGE 9 / 52 Installation and User guide –ECOROCK-5000 & BIOROCK Multirock Systems –10-10-2017

1.4 IDENTIFICATION

Before installing please copy the serial number of each tank on to the documents to be kept by the

customer (Appendix 5 of this Guide.)

1.5 HANDLING AND TRANSPORT OF THE TANKS

Two integrated slots on the bottom of the tank enable a safe movement by fork lift.

Four lifting eyes are situated on the top corners of each tank, enabling lifting by crane or JCB.

The tanks should be handled, transported and stored with care after delivery to avoid being

damaged.

When looking at the tank facing the BIOROCK® logo, the serial number is:

-On an identification tag inside the tank, and

/or

Marked as on the drawing below

-Engraved on the area to your right at the

bottom of the rounded top.

Marked as on the drawing below

MDetail of the identification plate inside the tank:

A. INSTALLATION GUIDE 2. OPERATING PRINCIPLE OF ECOROCK-5000 UNITS

PAGE 10 / 52 Installation and User guide –ECOROCK-5000 & BIOROCK Multirock Systems –10-10-2017

2. Operating principle of an ECOROCK Sewage Treatment Plant

A BIOROCK system is composed of a Primary tank and one or several ECOROCK treatment units

(Multirock installations). Initially the raw sewage enters the primary tank to provide separation and

the breakdown of organic solids (Primary Treatment). The sewage then passes through an effluent

filter before discharging into the ECOROCK Treatment Unit which incorporates the well proven aerobic

digestion process (Secondary Treatment) and filtration process (Tertiary Treatment).

In case of Multirock installation, and when more than three Treatment Units are installed in parallel

after a Primary Tank, the installation of a Flow Management System is necessary and highly

recommended.

2.1 THE PRIMARY TANK

The effluent (domestic wastewater composed of black water: origin toilets –and grey water: origin

kitchen, bathroom, laundry) enters the primary tank. This Primary Tank carries out the first basic phase

of wastewater treatment, that is separation of solids and fats by flotation (formation of a grease layer)

and by clarification (the suspended solids sink to the bottom of the tank by natural settlement).

Separated solids building up at the bottom of the primary compartment are called “primary sludge”.

This sludge breaks down in time by anaerobic digestion.

The primary tank should always be equipped with an efficient effluent filter. This filter holds back

remaining suspended solids, fats and other floating matter which enables a higher quality of pre-

treatment.

In case of Multirock installation, when a BIOROCK effluent filter is fitted into the Primary Tank, and

when the Primary Tank is of a volume of more than 7500 liters (included), a Ø110mm effluent filter

may be not sufficient for the flow and a Ø160 mm effluent filter may be necessary instead.

2.1.1 Ventilation of the Primary Tank

Any Primary tank should have a proper unencumbered low level and high level vent. The low level

vent should be connected directly on the outlet side of the tank and the high level on the inlet side

and should not be positioned more than 10 m1from the tank and at a minimum height of 4 m1with

a wind driven ventilator also fitted. The water inlet should be made air tight. All ventilation should

be checked with a smoke test.

2.1.2 Performance of the Primary Tanks (PT)

If the Primary Tank being used is not a BIOROCK tank, make sure that the quality of the effluent from

the PT meets the BIOROCK requirements. Proper ventilation of a PT is necessary, not only to avoid

smell problems, but also to evacuate the gasses produced. A Primary Tank generates malodorous

gases like hydrogen sulphide (H2S). Ventilation of the gasses is necessary to prevent H2S being

transformed into harmful sulphuric acid (H2SO4). Sulphuric acid will harm the biological process and

can cause degradation of the BIOROCK Media.

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