The BIODEC Cyclator™ wastewater decanter composite floating body has been developed and series-produced by Carbon Composites since 2018. The glass-fibre composite design provides 100% corrosion resistance, a service life exceeding 20 years and extremely simple installation in aggressive wastewater treatment environments.
The Cyclator™ Technology
The Cyclator™ is an innovative wastewater treatment technology developed by Hungarian engineers, whose key component is the unique Biodec™ decanter composite unit.
How it works:
- Operation: Continuous-feed, activated-sludge SBR (sequencing batch reactor) technology with cyclic phases (aeration, mixing, settling, decanting).
- Flexibility: Phases are adjustable to match the wastewater quality.
- Efficiency: Ensures complete nitrification, denitrification and biological phosphorus removal.
Key advantages over conventional methods:
- Chemical usage: Can be reduced to as little as 10%.
- Footprint: 30% less space required, since large secondary clarifiers are unnecessary.
- Energy consumption: Approximately 40% lower operating costs.
Results and references:
- Adoption: 23 municipal wastewater treatment plants have already been built in Hungary with this technology, and it is also used in industrial and international projects.
- Awards: Cyclator Ltd. received recognition at the 25th Hungarian Innovation Grand Prix.
Carbon Composites’ Manufacturing Role
During BIODEC development the previous stainless-steel floating body was replaced with composite. At the start of the project it was critical to select a base material that could guarantee a 20-year service life under extreme conditions in aggressive media. The composite solution also promised a significant improvement in buoyancy.
Due to the large size and complex geometry, closed-mould processes were not feasible, so the production tooling was designed for hand layup. The part quantities also allowed the use of this relatively long-cycle but reliable technology.
Trimming and drilling of the finished parts to the required tolerances were achieved using custom-built special templates – so-called jigs.
Technical Requirements & Compliance
The composite floating bodies meet specialised industrial requirements:
- Manufactured with outdoor UV and chemical-resistant gelcoat in RAL5024 colour
- Structurally withstands 300 kg loading on the outer rim, loaded on the inner rim without failure (non-destructive)
- Aesthetically flawless finish
- Holes machined to drawing-specified dimensions and tolerances
- Mating flanges milled flat to required tolerances
Applied Manufacturing Technologies
- Material selection specifically for aggressive media
- Large-part manufacture using laminating moulds
- Integration of profiled rib stiffeners, domes and metric brass inserts into the structure
- Cutting templates for precise mechanical machining and accurate fitment
BIODEC™ C Series – The Composite Decanter
The C Series is the latest member of the BIODEC™ family, whose composite floating body is manufactured by Carbon Composites. This model offers significant advantages over the stainless-steel version: complete corrosion resistance, lower shipping costs and extremely simple installation thanks to its low weight.
Technical Description
The BIODEC™ C is a circular decanter operating on the same air-cushion principle as the S Series. Thanks to the submerged weir-edge design it provides a near-constant volumetric flow rate. The unit features a unique solids-exclusion system and an emergency overflow function. It can be installed on the tank rim, making maintenance and possible relocation straightforward.
Thanks to its modular design, each unit can handle up to 400 m³/h throughput, but the system is infinitely scalable to suit any size of treatment plant. When multiple units are deployed, a special algorithm assists in precisely setting the outflow rate and fully utilising the decanting cycle time.
Key Advantages
- Constant flow: Stable output between 50 and 400 m³/h per unit.
- Modular design: Coordinated operation of multiple units provides unlimited capacity.
- Intelligent control: Algorithm-based operation that adapts to process conditions.
- Optimised cycle time: Utilises the full decanting time instead of pre-set values.
- Composite structure: Expected service life exceeding 20 years.
- Submerged weir edge: Prevents sludge suction.
- Emergency overflow: Built-in automatic shut-off mechanism.
- Contamination exclusion: The air-cushion design guarantees exclusion of floating solids and foam.
- Easy installation: Light weight, flanged connection for quick fitting.
- Cost-effective logistics: Low shipping and handling costs.