In our last post, we introduced aphron microbubbles — what they are and why their stability and electrostatic properties make them effective for flotation. This post covers how Tenco Hydro has integrated a third-party aphron generator into our DAF platform to create a hybrid system we call DAF+.
Tenco Hydro’s strength is system engineering and integration. Rather than developing a proprietary bubble generation device, we’ve focused on what we do best: taking a proven third-party aphron generator and engineering it properly into a complete, optimized flotation system. The result is a more capable DAF — not a different product category.
The Core Idea: Two Bubble Populations
A standard DAF system produces one population of bubbles — dissolved air microbubbles released at the pressurization stage. DAF+ introduces a second population: aphron microbubble froth produced by an integrated third-party generator and introduced at the point of contact in the flotation cell.
These two bubble populations work together. The dissolved air whitewater provides the high-volume bubble blanket your operators know and trust. The aphron froth provides a finer, more stable, electrostatically active bubble layer that improves attachment efficiency — particularly for fine solids and emulsified materials that are harder for standard DAF bubbles to capture reliably.
The aphron generator output is flow-paced to the DAF inlet — as influent flow or solids loading increases, aphron dosing adjusts automatically. This integration is handled through Tenco Hydro’s standard C2/C3 control platform, so operators manage one system, not two.
What Changes in the Design
Aphron injection at the release chamber. The release chamber is where bubble-particle contact begins in every Tenco DAF. In DAF+, aphron froth is introduced here alongside the dissolved air whitewater — so the particle meets both bubble types simultaneously at the moment of first contact.
Distributed injection along the flotation zone. Rather than a single contact point, DAF+ incorporates multiple injection points along the length of the flotation cell. This sustains bubble-particle contact throughout the tank rather than concentrating it at the inlet. It also compensates for the natural tendency of some particles to settle mid-tank before reaching the skimmer.
Reduced recirculation rate. Because the aphron froth contributes meaningful bubble volume, DAF+ can operate at a lower recirculation ratio than a standard DAF — typically 30–35% versus the conventional 50%. This directly reduces the size and energy demand of the pressurization system.
What Stays the Same
Everything that makes a Tenco DAF reliable remains in place: the 87% dissolved air saturation efficiency pressurization system, the chain-driven stainless skimmer mechanism, the pyramidal release chamber geometry, and the full range of controls from C2 through C3 SCADA-ready configurations.
The pressurization system is a feature, not a liability. It gives operators a real performance dial — recirculation rate is adjustable in response to influent load swings, providing active process control that a single-mechanism flotation system cannot match.
Where DAF+ Makes the Most Sense
DAF+ is particularly well-suited to applications where standard DAF is performing adequately but leaving performance on the table: fine solids carryover, variable-load industrial streams, high-strength FOG applications, and municipal secondary flotation thickening where consistent effluent quality is critical regardless of loading variation.
It is also a natural upgrade path for facilities with an existing Tenco DAF installation — the fundamental platform is the same, the infrastructure is already in place, and the aphron generator integrates as an add-on component rather than a full system replacement.
In our next post, we’ll address a question we hear often from municipal customers: if your DAF has been running reliably for 30 years, why change the platform at all?