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PROCESS DESCRIPTION AND GUARANTEES

1.0 Summary of Influent water analysis


COMBINE
WASTE

AQ218

AQ212

AQ232

AQ229

AQ222

AQ238

AQ239

HRG

HRG

HRG

UTILITIES

SAN

COMPOUNDING
SUMP PUMP

COMPOUNDING
SUMP PUMP

WASTE
WATER HEAT
RECOVERY
EXCHANGER

WASTE
WATER
TRANSFER
PUMP

ACIDIC
WATER
SUMP PUMP
(UPSET CASE)

WASTE
WATER
STRIPPER

SAN SUMP
PUMP

COMPOUNDING
SUMP PUMP 1

COMPOUNDING
SUMP PUMP 2

SE 3403

SP 3019

SP 3020

SC 6001

SP 4018

SP 5012

SP 5013

ABS30 P1 PF
200843 1

ABS30 P1
PF 200849
1

ABS30 P1 PF
200849

ABS60 P1
PF 200973
1

ABS40 P1
PF 200870
1

ABS30 P1 PF
200843 1

ABS30 P1 PF
200843 1

Flow Rate, Average


(m3/hr)

71.2

3.6

6.4

2.9

3.3

4.6

92

Flow Rate, Normal


(m3/hr)

71.2

15

45

22

15.5

15.5

191.2

Flow Rate, Peak


(m3/hr)

89

15

45

7.2

22

15.5

15.5

209.2

Frequency of Flow
(Continuous/
Intermittent)

Continuous

2 time per
day

1 TIME/10
DAYS

Continuous

6 times per
day

Intermittent on
level control

Intermittent on
level control

Continuous

3hr

2 hrs/pump
out

0.6
hr/pump
out

very infrequent

7 times/day

2.1

0.55 hr/pump
out

23

567

500

500

200

1250

563.0

1800

4000

1500

332

300

2500

1800.1
1001.0

PLANT UNIT

STREAM ID
PETROKEMYA EQUIP TAG NO.

PFD (or PID if former not available)

2
3

Duration, if
Intermittent
(time/interval)

pH

BOD at 20 deg C
(mg/litre)

COD (mg/litre)

Total Suspended
Solids (mg/litre)

30

300

13500

500

178

Phosphorus (PO43 )

90

Sulfate

2600

348

16

16

16

10

TDS

2898

3000

110

110

110

21

Total Alkalinity (As


CaCO3)

35

35

35

35

Total Hardness (As


CaCO3)

85

760

25

40

25

40

Ca Hardness (As
CaCO3)

85

760

25

40

25

40

Chloride

20

1850

20

20

20

20

Sodium

158

740

60

60

60

60

10

11

Operating condition

B.L wwpt
package at
grade:133
kPag

B.L wwpt
package at
grade:170
kPag

B.L wwpt
package at
grade:155
kPag

B.L wwpt
package at
grade:133
kPag

B.L wwpt
package at
grade:200 kPag

B.L wwpt
package at
grade:260 kPag

12

Operating
temperature in deg
cent.

60.5

50

60

53

49

49

60

Organic chemical
Composition

35

444

70.2
2037.7
2399.5
5.5
100
100
90.9
160.0

59.4

13

14

Acrylonitrile

1,3 Butadiene

Styrene

Oil & Grease


Destination
(AS PER FEED DESIGN)

3.2

2.1

3.5

0.171

0.03

4.7

0.5

12

0.64

1.4

0.017

WASTEWAT
ER
PRETREAT
MENT

WASTEWATE
R
PRETREATME
NT

WASTEWAT
ER
PRETREAT
MENT

WASTEWAT
ER
PRETREAT
MENT

1.7
WASTEWATE
R
PRETREATME
NT

170

11.3
0.6

1702

85.8
1.3

Note : Chloride forms the predominant anion concentration

1.0

Combined wastewater analysis


Average Flow rate:
Design Margin:
Average Design Flow rate:
Design Normal flow rate
Design Peak flow rate
pH:
BOD:
COD:
TSS:
Phosphorous (PO4):
Sulfates:
TDS:
Feed Temperature:

92m3/hr
10%
101.2m3/hr
191.2 m3/hr
209.2 m3/hr
2 to 3
563 ppm
1,800 ppm
1,000 ppm
70 ppm
2,012 ppm
2,375 ppm (@ pH of 2 to 3; before
neutralization)
59.2 Deg. C

Other assumed parameters:


Ca + Mg:
Na + K:
Alkalinity:
1.1

Required Treated Water Analysis after the new system:


pH:
Temperature:
Total Dissolved Solids:
Calcium (as CaCO3):
Sodium (as Na):
Total Alkalinity (as CaCO3):
Sulfate (as SO4):
Chloride (as Cl):
Iron (as Fe):
Silica:
Chlorine Residual:
Suspended Solid:
Turbidity:

1.2

~100 ppm
~50 ppm
~110 ppm as CaCO3

Brine water composition:


pH:
Temperature:
Total Dissolved Solids:
Calcium (as CaCO3):
Sodium (as Na):
Total Alkalinity (as CaCO3):
Sulfate (as SO4):
Chloride (as Cl):

8.3~8.6
< 50C Max.
< 110 mg/l
< 78 mg/l
< 30 mg/l
< 80 mg/l
< 80 mg/l
< 30 mg/l
< 0.06 mg/l
< 0.52 mg/l
0.32~1.0 mg/l (by others)
Nil
< 1.0 NTU
6.8-7
< 50C Max.
< 65,000 mg/l
< 20 mg/l
< 21,500 mg/l
< 35 mg/l
< 40,000 mg/l
< 3500 mg/l

2.0

Waste Streams:
2.1

Waste water from self cleaning filter


Waste water Quantity:
300 Liters per

2.2

Sludge from Primary Clarifier


Sludge Quantity:
3 to 6 Ton per day (Dry)

2.3

Sludge from Biological System


Sludge Quantity:
30 tons per day biological sludge (slurry)

2.4

Characteristics of Reject Water to Sea


Brine Quantity:
126 m3/day meeting RC-2010 table 3C.

3.0

Process Description

3.1

General
The plant described herein is aimed at the re-use of wastewater from achemical
processing plant and the reduction of the waste components to solids, which are far
easier to dispose.
Several equipment make the system.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

Self Cleaning Filter


Equalization
Chemical Neutralization
Coagulation
Flocculation
Clarification
Oxidation
Chemical Sludge Dewatering System
Oriented Spray Cooling system
Activated sludge Biological Treatment Bioreactor
Membrane Separation (MBR) Process
Advanced Oxidation Polishing System
UV Ozone destruction system
Hardness Removal Unit (Softener) - Polishing
Primary RO Unit
Brine Recovery RO Unit

3.2

Process Outline

3.2.1

Self Cleaning Filter


Feed wastewater is combined from all streams and then screened, so particles larger
than 1 mm will be removed.

This is done utilizing a self-cleaning filter working as a sieve preventing passage of


large objects self-cleaning filter is placed on the top of the equalization tank.
Periodically, the self-cleaning filter will be backwashed automatically to flush the
accumulated solids.
Waste solids will be collected through sludge dumpster for further disposal (By
others).
A fully self-cleaning strainer with an automatic scraper Strainer operates as follows:
The fluid enters the strainer vessel and passes down into the filter screen, where the
inside to outside flow traps the debris on the inside of the screen.
The flow is uninterrupted and the strained clean fluid continues into the outer ring of
the strainer body and exits through the outlet nozzle.
The scraper blades and brushes make direct contact with the screen, ensuring that all
particles are removed from its surface, including sticky contaminants like sludge,
residue, etc.
The blades also act as a pulverizing agent, capable of breaking up large solids so that
they can be more easily evacuated through the blow down line.
The blow down line on the scraper strainer is an opening at the bottom of the unit,
where contaminants collect during the scraping cycle.
There are two timers, one to control the interval between scraping cycles and another
to control the length of time that the blow-down valve shall remain open at the end of
a scraping cycle.

For example, if a scraping cycle lasts two minutes, particles can accumulate at the
bottom of the unit pending the opening of the blow down valve.
The blow down valve would be programmed to open for ten seconds at the end of
each minute of the scraping cycle, making for two blow downs per cycle, with this
logic of operation, the scraper Strainer uses much less fluid for self cleaning.
The unit uses only feeddirty water for blow down.
Fluid loss can be adjusted for minimum loss requirements.
Blow-down operation is controlled by a pneumatically actuated ball valve.

3.2.2

Equalization
Filtered wastewater from self-cleaning filter outlet will be balanced in the
equalization tank.
Wastewater generated from softener and decanted water from belt press system are
also recycled back to this equalization tank for re-processing.
The tank will balance flow to subsequent sections downstream.
Tank is sized to hold up around 2.5 hours time based on intermittent peak flow of 209
m3/hr

3.2.3

Chemical Neutralization
The wastewater is then pumped to a chemical neutralization process where caustic
soda is used to neutralize the water and raise pH to around 9.5 10.5 to precipitate all
heavy metals, phosphates, and some COD/ BOD.
As the pH value of the wastewater increases beyond about 10, calcium ions present
will react with the phosphate, to precipitate in hydroxylapatite:
10 Ca2+ + 6 PO43- + 2 OH- Ca10(PO4)*6(OH)2

3.2.4

Chemical Coagulation
The same chemical neutralization tank will act as a coagulation tank. When pH is
raised, all heavy metals, phosphates, and suspended solids will form coagulates that
can be settled easily in the clarifier.Flocculant is added also to facilitate this
precipitation.

3.2.5

Flocculation
Before entering to the Lamella Clarifier, water is first fed to the Flocculation Tank.
Water enters in flocculation chamber in which slow paddle-type agitator is provided
for gentle mixing.
The mixing shall not be too rapid,so it will break or shear the formed flocs, nor too
slow so flocculation is not thoroughly mixed or precipitate inside the flocculation
tank.Liquid Polyelectrolyte is added for flocculation of the coagulated particles.
Sufficient residence time is provided in this chamber for particles to become heavy
before entering into Lamella Clarifier.

3.2.6

Clarification
The water then overflows to inclined plate clarifier to remove all settled particles.
The inclined plate clarifier is space-saving method of optimizing sedimentation
utilizing highly compact settlers with very small footprints.
Its success is due to a number of factors mainly the unique, flow control system,
which represents a breakthrough in modern plate separator design and has contributed
significantly to the excellent reliability and efficiency of the unit.

How it works
1. Effluent enters the unit through the inlet pipe (brown arrow) and flows downward
through the inlet chamber in the centre of the unit, entering the plates through
openings in the bottom.
2. As the liquid flows upward the solids settle on the inclined, parallel plates and slide
into the hopper at the bottom of the unit. In the hopper, the sludge is thickened prior
to discharge through the sludge outlet (brown arrow).
3. The clarified liquid leaves the plate assembly through openings at the top and is
discharged into collection channels leading to the clarified water outlet (blue arrow).
4. The openings at the top of the plate assembly are designed to create a pressure drop
across the collection channels, ensuring that the flow is distributed uniformly between
the plates and that the full area is utilized. This is a patented flow control feature

3.2.7

Chemical Oxidation water tank


This process will utilize 50% hydrogen peroxide (H2O2) to breakdown the hard
(refractory) COD and convert it to biodegradable COD grade, so it can be removed by
subsequent biological treatment.
Tank is working on the overflow concept to maintain fixed retention time.
Overflow from oxidation water tank will collect in MBR feed tank.
Water is pumped from this tank to the aeration tank through the spray cooling system.
Nutrient is dosed at the inlet of the aeration tank to increase the COD removal rate
and oxygen uptake rate. The flow will be linked to the flow from the MBR permeate
pump.
Sulfuric acid is also dosed to acidify the water before feeding the biological system to
have neutral pH. pH at the outlet of the MBR pump will adjust the acid dosage.

3.2.8

Sludge dewatering system


Sludge from the lamella clarifier is sent to the dewatering press to form sludge cake
for disposal.
Part of the sludge is recycled back to the flocculation tank to help in seeding the
formed flocs.
Decanted filtrate water is recycling back to the equalization tank.

3.2.9

Oriented Spray Cooling System


Since the water temperature is higher than the acceptable temperature for biological
process, it will be cooled by the means of spray cooling on the top of the aeration
tank.For this purpose a special spray cooling system is envisaged here.
Spray ponds offer significant advantages over mechanical draft cooling towers
including superior simplicity and operability, lower preferred power requirements,
and lower capital and maintenance costs.
With a conventional spray system, the spray nozzles are arranged in a flat bed and
spray upward. Although the heated air surrounding the water droplets tends to rise, as
the water droplets fall back downward to the pond surface below, they apply a bulk
drag force on the air in the downward direction and tend to block the flow of air
through the spray region.
The result is stagnant air in the spray region during periods of low ambient wind
velocity and inefficient cooling.

With the OSCS, the spray nozzles are mounted on spray trees arranged in a circle and
tilted at an angle oriented towards the center of the circle. As a result, the water
droplets are sprayed toward the center of the circle, and they drag air into the spray
region.The warm air is concentrated in the center of the circle and rises, forming a
plume similar to a cooling tower.
Both of these effects work together to increase airflow through the spray region.
Increased airflow reduces the local wet bulb temperature of the air in the spray
pattern, promoting better heat transfer and more efficient cooling.
3.2.10 Activated Sludge Aeration Tank

Water cooled by the spray system falls in to the aeration tank.


In wastewater treatment processes, aerationintroduces air into the liquid, providing an
aerobicenvironment for microbial degradation of organicmatter.
The purpose of aeration is two-fold:
1) To supply the required oxygen to the metabolizing microorganisms and
2) To provide mixing so that the microorganisms come into intimate contact with the
dissolved and suspended organic matter.
Bacteria in the aeration tank will consume the available COD and BOD and remove it
so it can be processed by the subsequent stages without fouling the RO unit.
3.2.11 Membrane Separation - MBR
The bulk of COD/ BOD are removed in the biological process.
The process used in the plant is a membrane bioreactor system with submerged
membrane modules.
In the MBR tanks, the separation of the filtrate and sludge will be achieved by the
membrane modules that are installed inside the tank.
For operation, the membrane filtration module will be fully immersed into the sludge.
Permeate pumps will withdraw the treated water to store in MBR permeate / Cleaning
tank.
The MBR tank will be provided with sludge airlift system to re-circulate the sludge
back in to the aeration system

Surplus Sludgge
The produced
T
d surplus sluudge in the bbiological taank will be ddischarged when
w
a certaiin
value for the suspended solids
s
is reacched.
The discharg
T
ge is done by
y using a sooak truck peeriodically too remove slludge directlly
frrom the tankks.
During operaation the usuual concentraation of the suspended ssolids reachees up to 3,5000
D
too 5,500 mg/lliter.
The adjustmeent of solids shall be based on operattion setting aaccording to manual dailly
T
m
measurement
t.
R
Regeneration
n of the mem
mbrane moduules
C
Chemical
cleaaning of the filtration membranes haas to be carriied out from
m time to timee.
This is necessary becauuse of the ddeposits of organic
T
o
andd/or inorganic substancees
acccumulatingg on and insside the filtrration membbrane. The regeneration
r
n frequency is
siignificantly influenced by
b the charaacteristics off the liquid m
media and thhe differential
prressure used
d in the filtraation processs.
Regeneration
R
n shall be performed
p
inn the same bioreactor tank and shhall not neeed
seeparate systeem.
A CIP from MBR perm
meate /cleaninng tank is provided
p
forr chemicallyy cleaning thhe
sy
ystem.

3.2.12 Advanced Oxidation Process


Advanced oxidation processes are reliable means of meeting new environmental
standards.They also offer capital and operating cost savings compared with
conventional treatment processes.

In general oxygen, coming from air compressor, Pressure Swing Adsorption (PSA) is
an economic technology to separate air constituents (principally nitrogen and oxygen)
by selective adsorption of these components on molecular sieve.
The efficiency for oxygen is between 90 to 93%. The regeneration phase or
desorption is carried out by decreasing the pressure down to atmospheric pressure
PSA systems, has to be treated to a special quality before entering the ozone
generating unit.
The performance is either based on carrier gas quality such as the moisture and
hydrocarbons content, nitrogen content and feed gas pressure as well as the
introduced power to form ozone molecules and the gas temperature. For the feed gas
system to function properly the feed gas should be cooled down to an optimum
temperature. The ozone generator itself should be cooled down with service water as
low as possible to reach high ozone yields and higher half-life for ozone molecules.
To analyze the result of the ozone production, the ozone yield is measured by a
monitoring system. Once ozone gas has been generated, it must be transferred to the
water to be treated using the most effective diffusion system possible. Often more
than one ozonation step is used. To control the right ozone dose, residual ozone in
water monitoring system is used. Depending on the reaction and retention time where
ozone is reacting and being dissolved in the water the process is operated on higher
ozone introduction than the water can accommodate. Residual degassing ozone has to
be treated with residual ozone destructors making the process itself safe and
environmental-friendly.

3.2.13 UV system

After Ozone addition by means of advanced oxidation system influent will pass
through UV system.
UV system is a physical process that instantaneously neutralizes microorganisms as
they pass by ultraviolet lamps installed inline. Also it will help destructing the excess
ozone that may be present in the water.
The process adds nothing to the water but UV light, and therefore, has no impact on
the chemical composition or the dissolved oxygen content of the water. In that
respect, it ensures compliance with the wastewater effluent discharge regulations.
3.2.14 Hardness removal unit (Softener)
UV treated wastewater passes through the softener to remove water hardness for full
removal of calcium and magnesium.
The softener once its capacity is consumed, it will be regenerated with sodium
chloride brine solution.
The regeneration method is co-current design.

3.2.15 Primary RO Unit


The system is provided with antiscalant dosing pumps to dose metered quantities of
this chemical in the filtered water upstream of the cartridge filters. This reduces the
risk of scaling in the membranes.
This water is filtered further through cartridge filter housing. Cartridge filter with 5micron rating installed at the inlet of the R.O. train protects the high pressure pump
and the membranes from suspended solids that may have passed through the media
filter.
The high-pressure pump feeds the filtered and chemically treated raw water to the
Reverse Osmosis membranes at high pressure.
When raw water at high pressure is fed to the Reverse Osmosis membrane, almost
pure water passes through the membrane while salts are retained in the brine side.
The treated from Reverse Osmosis membrane unit is collected in a manifold, to
storage tank. Brine reject from the RO membranes is continuously removed and will
be treated in the Brine Recovery RO unit
3.2.16 Brine Recovery RO Unit
The brine from the Primary RO is sent to this unit for further recovery of the water to
reduce the amount of water disposed to the sea. The process is similar to the
Secondary RO unit.
Summary:
After full treatment, water from both RO units will be combined and sent to client for
reuse.

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