WASTE WATER TREATMENT

INTRIDUCTION
This proposal, as required by Panasonic Appliances Air-Conditioning Malaysia Sdn. Bhd. Is to
supply and install 10-15m3/h Wastewater Treatment Plant at Panasonic Appliances AirConditioning Malaysia Sdn. Bhd. No.17, Jalan Puchong, Taman Perindustrian Subang Utama,
Seksyen 22, 40300 Shah Alam, Selangor D.E. This wastewater treatment plant is proposed by
Chemkimia Sdn. Bhd., which hereby the contractor responsible for the system.

OBJECTIVE
The wastewater treatment plant is designed to treat additional wastewater from factory due to
increase in production line (shifting from MCM-PJ) in order to meet the Third Schedule
Environment Quality Act 1974, Environmental Quality (Sewage and Industrial Effluents)
Regulations 1979, Parameter Limits of Effluent of Standard B.

PROPOSED 10-15M3/H WASTEWATER TREATMENT PLANT PROCESS

Raw

Chemical
treatment & DAF
System

Biological
System

Carbon Adsorption
& Membrane
Filtration

Effluent

Sludge for
disposal

Sludge Dewatering

DESIGN CRITERIA

Influent design flow rate

Design flow rate

: 10-15 m3/h

Design operation

: 24 hours per day

Design parameter
Parameter

pH
COD, mg/L
BOD (5 days, 20 deg)
TSS
Mercury (as Hg)
Cadmium (as Cd)
Chromium hexavalent
Arsenic
Cyanide
Lead
Chromium trivalent
Copper
Manganese
Nickel
Tin
Zinc
Boron
Iron
Phenol
Free chlorine
Sulphide
Oil & grease

Unit
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L

Raw water Raw water

04/12/07
50/12/07
9.02
9.06
740
850
280
310
110
86
ND(<0.001) ND(<0.001)
ND(<0.01) ND(<0.01)
ND(<0.02) ND(<0.02)
ND(<0.01) ND(<0.01)
ND(<0.01) ND(<0.01)
0.01
ND(<0.01)
ND(<0.02) ND(<0.02)
0.18
0.36
1.65
2.34
0.23
0.21
ND(<0.02) ND(<0.01)
0.45
0.43
8.46
12.4
2.54
2.66
0.2
0.1
ND(<0.1)
ND(<0.1)
ND(<0.2)
ND(<0.2)
28
34

Raw water
05/12/07
9.06
760
310
93
0.002
ND(<0.01)
ND(<0.02)
ND(<0.01)
ND(<0.01)
ND(<0.01)
ND(<0.02)
0.36
2.34
0.21
ND(<0.01)
0.43
12.4
2.66
0.1
ND(<0.1)
ND(<0.2)
34

Standard
B
5.5-9.0
100
50
100
0.05
0.02
0.05
0.10
0.10
0.5
1.0
1.0
1.0
1.0
1.0
2.0
4.0
5.0
1.0
2.0
0.50
10

PROCESS DESCRIPTION

Equalization sump and concentrate sump (Existing)

The variation of heavy metals and contaminants are observed in all influent wastewater.
In the consideration of treatment process fundamentals, it was assumed, for the purpose of
simplifying the analysis, that the influents are constant. If instead a variable influent is
substituted for the assumed constant value, it can be often be shown that because of the variation
in the influent involved, there may be deterioration in performance from the optimum value that
can be achieved. Equalization sump is used to overcome the operational problems caused by
these variations and to improve the performance of the downstream processes.
Thus all the waste water will be channel to the Equalization Sump prior to any treatment
process. The equalized wastewater is then transferred into the treatment plant by submersible
pump which is control by the sump water level. A flow meter is installed to measure the
pumping flow rate to the Oil and Grease Trap.

Oil & grease trap (O&G 201)

Oil and Grease Trap capture the oil and grease from the flow of wastewater by slowing down the
flow of greasy water through the grease trap and allowing it to cool. As it cools, the grease and
oil separate out of the water and float to the top of the trap. The cooler water continues to flow
down the drain pipe to the Coagulation Tank while baffles prevent the accumulated grease and
oil from flowing out of the grease trap.

Coagulation Tank (CT 202)

In the Coagulation Tank, chemical coagulation is dosed in at constant dosage based on the
running of transfer pump. The pH in this tank will be maintained at correct pH in order to obtain
good formation of floc using caustic. Agitator is used to attain good mixing.

Flocculation tank (FT 203)

After the formation of fine floc, polymer will be added at constant dosage based on the running
of transfer pump to further agglomerate the fine floc. This will help to enhance the separation in
the next process. A slow/optimum speed agitator is used to attain good mixing while not
breaking the big floc formed.

Dissolved air flotation (DAF 204)

Dissolved Air Flotation (DAF) is the process of removing suspended solids, oils and other
contaminants via the use of air bubble flotation. Air is dissolved into water, mixed with the waste
stream and released from solution while in intimate contact with the contaminants. Air bubbles

form, attach to the solids, increase their buoyancy and float the solids to the waters surface. A
percentage of the clean effluent and injected into the DAF separation chamber.
The dissolve air comes out of solution, producing millions of microscopic bubbles. These
bubbles attach to the solids and float them to the surface where they are mechanically skimmed
and removed from the tank. Dissolved air flotation systems are designed to remove fats, oil &
grease (FOG), suspended solids, food/animal production/processing wastes, industrial wastes,
hydrocarbon oils/emulsions and many other contaminants. Clarification rates as high as 97% or
more can be achieved using dissolved air flotation systems.

Biological aeration tank (AT 205)

Effluent from the DAF will enter the Biological Aeration Tank where the organic matter will be
digested by the bacteria. Fine air bubble will be supplied by blower through air diffuser to
maintain the dissolve oxygen level in the tank.

Sedimentation tank (ST 206)

After aeration process, water will be channeled to Sedimentation Tank where activated sludge
containing bacteria will settle and the supernatant will flow to the filtration process. The settle
sludge will be returned to Aeration Tank by using a RAS pump. In the occasion where MLVSS
is too high, part of the activated sludge will be removed.

Carbon break tank (CBT 207)

Effluent from the Organic Settling Tank will enter this tank which is acts as a holding tank for
Activated Carbon Filter to ensure the smoothness of the operation in text process. This tank also
functions as the storage tank for the backwash usage.

Activated carbon filter (ACF 208)

Its function is to further clarify the effluent from biological system and to remove suspended
solid and dissolve organic matter. The suspended solid and dissolved organic are removed by the
passage of water in a down flow mode through carbon contained in a pressure vessel Automated
backwash sequence will be initiated by timer to remove the accumulated particles in the vessel
and recover its flowrate as well as preventing media hardening.

Continuous micro filtration (CMF 209)

The filtered water from Activated Carbon Filter will be passed thru the CMF for further
polishing to remove fine suspended solid smaller than 0.2micron from the previous process, thus
producing crystal clear effluent.

Final discharge tank (FDT 210)

The filtrate from the CMF will be pH adjusted (if necessary). If the pH reading is out of the
permitted range, it will be automatically returned back to the Equalization Sump. At the same
time, a flow meter with totalizer will be installed to display the flow rate and record the total
discharge treated water.

Sludge thickener (STT 211)

The waste sludge from the DAF will be transferred to this tank for further concentration. The
overflow from the Sludge Thickener Tank returns back to Equalization Sump.

Filter press (existing)

An air diaphragm pump will pump the concentrated sludge from the bottom of the Sludge
Holding Tank to Filter Press for the dewatering process. The water from the dewatering process
will flow back to the Equalization Sump. The pressed sludge can be packed in sludge cloth bag
or metal container depends on the local authority requirement before sending for further
treatment or storage.

EQUIPMENTS SPECIFICATION

Equalization tank
Equalization tank
Dimension

: 8m 4m 4.5m (Existing old WWTP)

Capacity

: 144m3

Material

: Concrete with FRP lining

Quantity

: 1 unit

EQ Pump
Type

: Submersible

Brand

: Goulds

Model

: GDOMO20T/B

Material

: Stainless steel

Capacity

: 15m3/h @ 11m, 1.5kW/415VAC

Quantity

: 2 units (PUM231 & PUM232)

Level Switch
Type

: Ball float

Brand

: Faes

Material

: Plastic

Quantity

: 3 units (LS281H, LS281M, LS281L)

Flow meter
Type

: Insertion electromagnetic remote display

Brand

: Burkert

Model

: 8025 (transmitter), 8041 (sensor)

Quantity

: 3 units (LS281H, LS281M, LS281L)

Oil & grease trap

Oil & grease trap
Dimension

: 1.5m 0.6m 1.235m

Capacity

: 1.0m3

Brand

: Saint Dizier

Model

: IHDC 01/0

Material

: M/S

Quantity

: 1 unit

Coagulation tank
Coagulation tank
Dimension

: 2m 2m 1.5m

Capacity

: 6.0m3

Material

: FRP

Quantity

: 1 unit

Coagulation mixer
Type

: Top entry

Brand

: Daqchem

Model

: 50G-150

Capacity

: 1.1Kw/415VAC/290rpm

Material

: Stainless steel 316 shaft/impeller

Quantity

: 1 unit (MIX251)

pH meter
Type

: Immersion panel mount

Brand

: B&C

Model

: PH7685

Quantity

: 1 unit (PH271)

Flocculation tank
Flocculation tank
Dimension

: 2m 2m 1.5m

Capacity

: 6.0m3

Material

: FRP

Quantity

: 1 unit

Flocculation mixer
Type

: Top entry

Brand

: Daqchem

Model

: 50G-150

Capacity

: 1.1Kw/415VAC/290rpm

Material

: Stainless steel 316 shaft/impeller

Quantity

: 1 unit (MIX251)

Dissolved air flotation (DAF)

Dissolved air flotation
Dimension

: 1.5m 4m 3.5m

Capacity

: 21.0m3

Material

: SS304

Quantity

: 1 unit

Recirculation pump
Type

: Centrifugal

Brand

: Nijhuis

Model

: ZLK

Capacity

: 7.5kW/415VAC

Quantity

: 1 unit

Skimmer motor
Brand

: Nord

Model

: SK02050-AZD-63L/4

Capacity

: 7.5kW/415VAC

Quantity

: 1 unit

Air compressor
Type

: Piston-reciprocating

Brand

: Dancomair

Model

: PEC1202S

Capacity

: 1.5kW/240VAC/9bar

Quantity

: 1 unit

Sludge pump
Type

: Air operated diaphragm

Brand

: Wilden

Model

: P4/AAPP/WF/WF/WF/014

Capacity

: 306.5Lpm (max), 8.6bar (max)

Material

: Aluminium body, wilflex diaphragm

Quantity

: 1 unit

Biological aeration tank

Biological aeration tank
Dimension

: 7m 7m 4m

Capacity

: 196.0m3

Material

: Concrete with FRP lining

Quantity

: 1 unit

Sedimentation tank
Sedimentation tank

Dimension

: 4m 4m 3.5m

Capacity

: 40.0m3

Material

: Concrete with FRP lining

Quantity

: 1 unit

pH adjustment tank
pH adjustment tank
Dimension

: 1m 1m 1.2m

Capacity

: 1.2m3

Material

: FRP

Quantity

: 1 unit

pH meter
Type

: Immersion panel mount

Brand

: B&C

Model

: PH7685

Quantity

: 1 unit (PH271)

Carbon break tank

Carbon break tank
Dimension

: 2.4mDia 2.4mH

Capacity

: 10m3

Material

: HDPE

Quantity

: 1 unit

Level Switch
Type

: Ball float

Brand

: Faes

Material

: Plastic

Quantity

: 3 units (LS281H, LS281M, LS281L)

Activated carbon filter

Activated carbon filter
Dimension

: 1.219mDia 1.524mH

Capacity

: 1.78m3

Material

: M/S

Quantity

: 1 unit

Continuous micro filtration

Continuous micro filtration-submerged (CMF-S)
Type

: Submerged

Brand

: Memcor

Model

: CMF32S10T

Capacity

: 10-30m3/H

Membrane

: Polypropylene

Pore size

: 0.2micron

Quantity

: 1 unit

Final discharge tank

Final discharge tank
Dimension

: 1.8mDia 2.15mH

Capacity

: 5.4m3

Material

: FRP

Quantity

: 1 unit

Flow meter
Type

: Insertion electromagnetic remote display

Brand

: Burkert

Model

: 8025 (transmitter), 8041 (sensor)

Quantity

: 1 unit (FM275)

Sludge thickening tank

Sludge thickening tank
Dimension

: 2.0mDia 3.5mH (2.5mH+1.0mCone)

Capacity

: 10m3

Material

: HDPE

Quantity

: 1 unit

Collection sump
Collection sump
Dimension

: 2.0m 2.0m 1.5m

Capacity

: 6m3

Material

: Concrete with FRP lining

Quantity

: 1 unit

Sump pump
Type

: Submersible

Brand

: Goulds

Model

: GDOMO20T/B

Material

: Stainless steel

Capacity

: 30m3/h @ 7m, 1.5kW/415VAC

Quantity

: 1 unit (PUM236)

Level Switch
Type

: Ball float

Brand

: Faes

Material

: Plastic

Quantity

: 3 units (LS281H, LS281M, LS281L)

Coagulant tank
Coagulant tank
Dimension

: 1.13mDia 1.17mH

Capacity

: 1.1m3

Material

: HDPE

Quantity

: 1 unit

Level Switch

Type

: Miniature float

Brand

: Nohken

Model

: OLV-2F 1000

Material

: PP

Quantity

: 3 units (LS283H, LS283M, LS283L)

Polymer tank
Polymer tank
Dimension

: 1.556mDia 1.22mH

Capacity

: 2.2m3

Material

: HDPE

Quantity

: 1 unit

Level Switch
Type

: Miniature float

Brand

: Nohken

Model

: OLV-2F 1000

Material

: PP

Quantity

: 4 units (LS284HH, LS284H, LS284M,LS284L)

Caustic tank
Caustic tank
Dimension

: 1.13mDia 1.17mH

Capacity

: 1.1m3

Material

: HDPE

Quantity

: 1 unit

Level Switch
Type

: Miniature float

Brand

: Nohken

Model

: OLV-2F 1000

Material

: PP

Quantity

: 3 units (LS283H, LS283M, LS283L)

Acid tank
Acid tank
Dimension

: 1.13mDia 1.17mH

Capacity

: 1.1m3

Material

: HDPE

Quantity

: 1 unit

Level Switch
Type

: Miniature float

Brand

: Nohken

Model

: OLV-2F 1000

Material

: PP

Quantity

: 3 units (LS283H, LS283M, LS283L)

STANDARD OPERATION PROCEDURE

SYSTEM CHECKING FOR STARTUP

The operator should go around the plant to check for the following items:

Chemical tanks area

The following are the chemical tanks for the treatment plant:

Actipol tank
Polymer tank
Acid tank
Caustic tank

Operate should check to ensure:

a) The level in chemical tanks is sufficient for the treatment plant.
b) There is no leakage at chemical tank.
If the level of chemical in chemical tanks is in low level, operator should order
chemical (Actipol, acid and caustic) from supplier. For polymer tank, operator
needs to dilute polymer powder into JBA water.
o Polymer preparation
2 kg of Polymer into 2000L water or according to it proportion.

ATTENTION: Please use appropriate Personal Protection Equipment (PPE)

during handling of chemicals.

Pumps
1) For pump, ensure that the inlet and outlet valves are opened.
2) Do priming (for centrifugal pump) before run pump if previously has been
dismantled.
3) For the chemical dosing pumps, ensure outlet valves are opened and suction
pipe/hose are submerged in chemical solution.

 Stirrers
1) Ensure that the liquid level in the tank is suitable to start stirrer could be
damaged if run in empty tank.

Air blower

1) Ensure the outlet valve is open.

2) Ensure the gear box oil is above the minimum level at the sight glass
indicator.
3) Ensure the V belts are in good condition.

Air compressor

1) Ensure the outlet valve is open.

2) Drain manually any condensate presents in the air receiver or air filter by
opening the stop cock/nut.
3) Ensure the compressor oil is above the minimum level at the sight glass
indicator.

Process tanks
1) Ensure that the drain valve of each tank is closed.
2) Check for other valves in normal operating condition.
3) Check for leaking.