From 29% to 86% Ammonia Removal in Weeks: Rapid Nitrification at a Coking Plant

A coking plant treating ammonia distillation wastewater struggled with low ammonia removal efficiency and needed to accelerate the startup of a new secondary treatment system. By implementing a targeted bioaugmentation program using BioRemove COD and BioRemove AM, the facility improved COD removal, rapidly established nitrification, and enhanced overall system stability.

Benefits

• Stabilized effluent COD within two months
• Rapid establishment of nitrification
• Improved ammonia nitrogen removal efficiency
• Enhanced system stability under variable operating conditions
• Increased resistance to shock loads and high-temperature events

Application

A structured bioaugmentation program was implemented in phases to support system startup and improve treatment performance.

During early-stage operation, BioRemove COD was applied to accelerate the development of active biomass and enhance organic degradation. This phase focused on building sludge concentration, improving floc formation, and stabilizing effluent COD.

Once COD performance stabilized, BioRemove AM was introduced to initiate nitrification. This enabled rapid establishment of nitrifying bacteria and improved ammonia removal efficiency.

Throughout the program, operational adjustments were made to support biological performance, including:

• Managing the influent carbon-to-nitrogen (C:N) ratio
• Gradually increasing system loading as biomass activity improved
• Monitoring key indicators to maintain stable operating conditions

This phased approach allowed the system to transition efficiently from startup conditions to stable, full-scale operation.

Results

The bioaugmentation program delivered measurable improvements in both organic and ammonia removal performance:

• Effluent COD decreased to below 500 mg/L within one month and stabilized below 300 mg/L after two months
• Ammonia nitrogen removal efficiency increased significantly, from 29% to 86%
• Effluent ammonia nitrogen concentrations dropped from an average of 61.2 mg/L to 8.3 mg/L

Nitrification was successfully established within just five days of applying BioRemove AM, demonstrating a rapid system response. The system also showed strong resilience to operational challenges, including:

• High influent COD fluctuations
• Ammonia shock loading
• Elevated temperatures exceeding 40°C (104°F)

Despite these disturbances, the treatment system consistently returned to normal operating conditions within a short period, indicating improved biological stability and recovery capability. Additionally, biomass quality improved, with increased sludge concentration and enhanced flocculation and settling characteristics.

Conclusion

The implementation of BioRemove COD and BioRemove AM enabled the coking plant to achieve faster system startup, improved treatment performance, and greater operational stability. The bioaugmentation program enhanced both COD removal and nitrification while increasing the system’s ability to handle variable and challenging conditions.

Overall results included:

• Improved plant efficiency
• Lower operational costs
• Simplified and more stable operations