Design, construction and commissioning of a biological leachate treatment plant built for long-term compliance and closure planning
Aerofloat was engaged to design and construct a new leachate treatment plant (LTP) for Brisbane City Council’s Rochedale Landfill.
As the landfill approaches capacity and nears the end of its operational life, a reliable treatment solution was required to manage complex landfill leachate and ensure compliance with sewer discharge requirements.
Aerofloat designed and built a fully automated biological leachate treatment plant centred around Sequencing Batch Reactor (SBR) technology.
The facility incorporates activated sludge treatment, automated chemical dosing, sludge handling and dewatering systems, effluent balancing infrastructure, and advanced process monitoring and control to achieve reliable treatment performance and support long-term environmental compliance.
The new treatment plant provides Brisbane City Council with a robust, scalable and future-ready leachate management solution.
Through advanced biological treatment, proprietary Aerofloat technologies and intelligent automation, the system reduces operational complexity, improves environmental outcomes and supports long-term compliance with sewer discharge requirements.
A future-ready leachate treatment solution engineered for one of Brisbane's largest landfill sites.
Aerofloat was engaged to design and construct a new leachate treatment plant for Brisbane City Council’s Rochedale Landfill, as the site approaches capacity and nears the end of its operational life. The facility needed to reliably manage complex, high-strength leachate, including elevated ammonia and BOD, while consistently meeting sewer discharge requirements.
Aerofloat delivered a fully automated biological treatment solution centred on Sequencing Batch Reactor (SBR) technology, incorporating activated sludge treatment, chemical dosing, sludge handling and dewatering, effluent balancing, and advanced process monitoring and control. The plant is designed to treat an average of 28,000L of leachate per day at a loading of 30kg/day TKN, and includes Aerofloat’s proprietary AeroWave dewatering and Air Lock Syphon (ALS) decanting technologies to improve reliability and reduce ongoing operating costs.
Brisbane City Council’s Rochedale Landfill in Queensland required a new leachate treatment plant to manage leachate generated from landfill operations as the site approaches the end of its operational life.
Leachate generated within the landfill is collected through a network of underground landfill pods and transferred through client-operated pumping systems to Aerofloat’s treatment facility. Due to elevated ammonia concentrations, high biochemical oxygen demand (BOD) and variable wastewater characteristics, the leachate requires advanced treatment before discharge to sewer.
To address these challenges, Aerofloat developed a complete design-and-construct solution incorporating biological treatment, chemical dosing, sludge management, automation and supporting civil infrastructure. The treatment plant was designed to provide a reliable, long-term solution capable of consistently achieving discharge requirements while reducing environmental risk and supporting the site’s ongoing management strategy.
Aerofloat designed, built and is currently commissioning a comprehensive leachate treatment plant centred around a 10-metre diameter reinforced concrete Sequencing Batch Reactor (SBR).
The treatment process uses activated sludge technology, where naturally occurring microorganisms biologically break down contaminants present in the landfill leachate. The system relies on maintaining a healthy and stable population of microorganisms, or biomass, which continuously feeds on pollutants in the incoming wastewater stream.
As part of the commissioning process, Aerofloat recently completed sludge seeding, introducing an active population of microorganisms into the reactor. These microorganisms will remain within the biological process, continually treating incoming leachate as it enters the plant. To support the biological population, the process carefully controls pH levels and dissolved oxygen (DO) system levels and delivers oxygen through high-efficiency blower aeration systems.
Leachate is first transferred from the site’s existing storage and buffering infrastructure into the treatment plant, where it is fed into the SBR at a controlled rate. During the reaction phase, microorganisms consume organic matter and break down contaminants within the leachate. Aeration systems supply oxygen required for biological activity and nitrification, enabling the nitrification of ammonia within the reactor.
The treatment process carefully controls aerobic periods, and the option to provide anoxic periods if required, allowing both nitrification and denitrification to occur in the same reactor. This approach improves nitrogen removal efficiency and optimises treatment performance.
A range of chemical dosing systems support the biological process, including caustic for pH control, nutrient supplementation (MAP), Sucrose as a carbon source for denitrification, and treatment aids such as anti-foam. These chemicals help create the optimum operating conditions for biological treatment while assisting with the removal of contaminants, including nitrogen.
Following the reaction phase, the SBR enters a settling period. Aeration is stopped, allowing biological solids to settle naturally to the bottom of the reactor while a clarified layer of treated water forms above. This settling stage enables efficient separation of sludge from the treated effluent.
The settled sludge is transferred to dedicated sludge handling infrastructure for further processing. A key component of the facility is Aerofloat’s proprietary AeroWave sludge dewatering system, which dewaters sludge onsite to improve sludge handling efficiency, reduce disposal volumes and lower ongoing operating costs.
The clarified effluent is removed using Aerofloat’s proprietary Air Lock Syphon (ALS) decanter technology. The ALS system provides reliable decanting performance while minimising maintenance requirements commonly associated with conventional decanter systems.
Prior to discharge, treated effluent passes through balancing and monitoring infrastructure where water quality is continuously verified.
Online instrumentation in the SBR monitors parameters including pH, dissolved oxygen (DO), oxidation reduction potential (ORP), total suspended solids (TSS), conductivity and mixed liquor suspended solids (MLSS). Instrumentation in the effluent tank monitors pH, conductivity, and TSS.
A fully automated PLC, HMI and SCADA system provides 24-hour monitoring, process control, alarming and remote support capabilities, giving operators complete visibility of plant performance, trends and allowing proactive optimisation of treatment processes.
The Rochedale Leachate Treatment Plant is currently undergoing commissioning with completion date expected by mid-July 2026, with sludge seeding successfully completed and the biological treatment process being established ahead of full operation.
Once fully commissioned, the facility will provide Brisbane City Council with a technically robust and future-focused solution for managing landfill leachate.
The plant has been specifically designed to reduce nitrogen, BOD, TSS, and other contaminants to meet sewer discharge requirements. Continuous monitoring, advanced instrumentation and automated process controls enable operators to maintain water quality within specification and ensure treated effluent complies with council, utility and regulatory requirements prior to discharge.
The plant is designed to treat an average of 28,000L of leachate per day at a loading of 30kg/day Total Kjeldahl Nitrogen (TKN). The combination of advanced activated sludge treatment, intelligent automation and Aerofloat’s proprietary ALS decanting and AeroWave sludge dewatering technologies provides a reliable and sustainable approach to landfill leachate management.
By delivering a complete design-and-construct solution, Aerofloat is helping future-proof leachate management at Rochedale Landfill while supporting long-term environmental compliance, operational efficiency and responsible landfill closure planning.
To learn more about Aerofloat’s engineering expertise, contact enquiries@aerofloat.com.au.
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