Designing for phases, not for year twenty
Many plants are sized for a build-out flow that takes a decade to arrive, which leaves blowers, pumps and membranes running far below their sweet spot. A modular approach builds trains or tanks for the current phase and leaves space, piping stubs and controls capacity for the next. With MBR, extra membrane area can often be added inside the same tank footprint, so early phases carry less installed equipment.
Custom sizing: we cut, weld and assemble in Poughkeepsie, NY, so cartridge and module sizes can often be tailored to your existing tanks. Tell us your tank dimensions, or see custom sizes.
How Zyramic modules scale
Swing modules are named by decks and columns: a Swing-8-X-Y module holds X decks by Y columns of 135 ft² (12.5 m²) cartridges, from 135 ft² (12.5 m²) up to more than 11,800 ft² (1,100 m²) per module. That makes it straightforward to start with a partly populated frame and add cartridges as flow grows, or to add identical modules side by side. Palisade is available in single and double-deck versions of about 1,460 ft² (136 m²) and 2,940 ft² (273 m²).
Because every module type can also be rented for US projects, some owners rent capacity for an early phase or a construction period, then buy once flow is proven.
Who we work with
Zyramic does not build complete plants. We supply membranes to integrators and package-plant builders who supply tanks, blowers and controls, and we help engineers lay out modules so later phases slot in cleanly.
| Mild backwash (special cases only) |
|---|
| Backwashing is not a standard Swing operating mode and is not meant for routine use. Swing has been pressure-tested to 14.5 psi (1 bar) and held without breaking. If a site is in a bind even after relaxation and CIP, contact us; we may be able to work out a special mild-backwash procedure. |
Worked sizing example
Take phase 1 of a subdivision plant at 79,252 gpd (300 m³/day), growing to 237,755 gpd (900 m³/day):
| Item | US | Metric | Note |
|---|---|---|---|
| Average flow | 79,252 gpd | 300 m³/day | about 55 gpm (12,500 L/h) |
| Design flux (gross) | 11.8 gfd | 20 LMH | Zyramic design guidance |
| Derate for relaxation and cleaning | ~20% | ~20% | |
| Net flux | ~9.4 gfd | ~16 LMH | |
| Membrane area needed | ~8,409 ft² | ~781 m² | average flow ÷ net flux |
| Swing-8 cartridges | ~63 | ~63 | 135 ft² (12.5 m²) each |
| Peak factor | ~2.0 | ~2.0 | |
| Peak flow | ~158,503 gpd | ~600 m³/day | extra area, short-term higher flux, or equalization |
This is an illustration only; a real design also checks temperature, MLSS, redundancy and the cleaning schedule.
Tips for a smooth project
- Size for peak hour as well as average flow
- Invest in good fine screening up front
- Use temperature-corrected flux for cold-weather design
- Plan lifting access so modules come out easily
Next step
Most projects start with a short call or an email with flows and a sketch. We send back a preliminary module layout and a quote, then refine it with your engineer once the process design is firm. If you are still comparing processes, we'll help you choose the right approach for your site.
Sizing considerations
To give a useful recommendation we usually need:
- Phase 1 flow and full build-out flow
- Number of trains and redundancy requirement
- Tank depth and access for lifting modules
- Controls philosophy for adding trains
- Whether early phases could use rental modules
Most relevant product: Swing MBR. See also replacement membranes, rentals and how to choose.
Why engineers look at Zyramic flat-sheet modules
| Item | Details |
|---|---|
| Smaller sheets, less wear and tear | each sheet flexes less in service, and a damaged unit affects less area. |
| Strong wide membrane welds | designed to resist delamination over the membrane's life. |
| Thick, robust membrane | about 250 microns including support. |
| Assembled in Poughkeepsie, NY | of domestic and imported components. In our Poughkeepsie shop we cut and weld membrane sheets to plates, build module frames and assemble complete modules. For funded projects, tell us your domestic-content requirements and we'll review what we can document. |
| Buy, rent or replace | new modules, rentals and pilots for US projects, and replacement membranes that fit many existing cassettes. |
Performance and life depend on pretreatment, design flux and operation; flux figures are Zyramic design guidance, sized to each project.
Frequently asked questions
Can I add membrane area later without new tanks?
Often yes, if the original tank and frame were laid out for it. We recommend planning spare positions at the design stage.
Is a modular plant less robust than a field-built one?
Not inherently. Performance depends on design, pretreatment and operation more than on whether the plant is modular.
Do you supply the tanks and blowers?
No, we supply membrane modules and parts and work with your integrator or builder for the rest.
What information do you need to size phases?
Flows per phase, influent characteristics, effluent limits and the tank layout. The full application form on our quote page covers it.
How many phases should a modular plant have?
It depends on how predictable the growth is. Two to four phases are common; too many phases add controls and piping complexity.
Can a modular plant be relocated?
Skid and container systems can be, and membrane modules can be removed and reinstalled at a new site after cleaning and inspection.