a.

Process Flow Diagram

Figure 1: Process Flow Diagram of Chemical Waste Treatment Plant (Pilot Plant).

1
b. Process Description

The purpose of waste water treatment plant in pilot plant is to treat the waste water from the pilot
plant itself besides from chemical lab in faculty if the amount of waste water flowrate is
insufficient.

1. Inlet Screen

The process of treatment begins at the inlet screen. The flowrate entering the inlet screen is
2m3/day. The function of the inlet screen is to remove the solids in the waste water influent from
entering the next process because the existence of the solids can eventually damage the other
equipment such as pump.

2. Collection Tank

After waste water pass through the inlet screen, it then will enter the collection tank. The
function of collection tank is maintained the desired flowrate and to make the mixture
homogenous. Usually, agitator will be installed in the collection tank that acts as the mixer in
order to make sure the mixture of waste water is homogenous.

3. Chemical Dosing System

The process continued with waste water enter the chemical dosing system. There are 4 stages
available in this chemical dosing system which are grease trap, coagulation tank, pH
neutralization tank and flocculation tank. The amount of chemical used for the dosing will be
determined by jar test experiment that will be conducted earlier from the sample from the
collection tank. The function of the grease trap in the chemical dosing is to remove the grease
and oily chemicals from the waste water. Then, next stage in the chemical dosing is coagulation
tank which usually use ferric chloride as coagulant and the function is to coagulate the sludge
particle. pH neutralization tank is used to maintain the pH of the waste water by using either the
hydrogen bromide or sodium hydroxide depends on the amount of pH of waste water recorded.
Lastly, the flocculation tank. The chemical used is polymer and the function are to make the
sludge particle becomes larger or be called the floc.

4. Clarifier Tank

The next process will go to the clarifier. The function of clarifier is to separate the inorganic
sludge by settling it at the bottom of the clarifier using the concept of gravity. The effluent from
the clarifier will go into the sequence batch reactor (SBR) tank and sludge at the bottom will go
to inorganic sludge holder tank.

2
5. SBR Tank

The effluent from the clarifier will enter the SBR tank for the further process. SBR tank is a type
of activated sludge process for the treatment of waste water. SBR tank also treat wastewater
such as sewage or output from anaerobic digesters or mechanical biological treatment facilities
in batches. The organic sludge obtained from the tank will be directed to the organic sludge
holder tank by was pump. The treated waste water from SBR tank will go to the treated water
tank by using decant pimp. Plus, air blower will also be injected into SBR tank to reduce the
amount of COD from the waste water.

6. Inorganic/ Organic Sludge Holder Tank

This sludge holder tank purpose is to collect the organic and inorganic sludge from clarifier and
SBR tank respectively. Next, it will move to the filter press for process of the dewatering of
sludge and finally become sludge cake. The water removed from the filter press will enter again
the collection tank through the drain.

7. Treated Water Tank.

Finally, the treated water from the SBR tank will enter this tank. It is use to contain treated water
before go to filtering process by the filter pump. Two types of filter used in this filtering process
which are sand filter and carbon filter. Then, the water will be tested again in order to ensure the
standard amount had been achieved before go to the final discharge to drain.

3
c. Design Calculation of Mass Balance for Each Unit Operation

1) Inlet Screening

The inlet screening at IETS at the pilot plant are assume to be micro screening. According to
Metcalf & Eddy (1991) the percentage removal for suspended solid is 10% to 80%, the
average percent removal are 55%.

Table 1: The Initial Value of Parameters in the Inlet screening

Parameter Average value

Suspended Solid (SS) 300 mg/L

COD 800 mg/L

BOD 500 mg/L

pH 4.8

For Solid Suspended removed in the screening.

𝑚𝑔
𝑆𝑆𝑜𝑢𝑡𝑙𝑒𝑡 = (1 − 0.55)𝑥 300 𝐿

𝑚𝑔
= 135 𝐿

2) Collection Tank

In the collection tank that will no reduction occurs for suspended solid, COD and BOD
because collection tank to collect the waste and to make the waste homogenous.

4
3) Chemical Dosing

Table 2: The Initial Value of Parameters in the Inlet of chemical dosing tank.

Parameter Average value

Suspended Solid (SS) 135 mg/L

COD 800 mg/L

BOD 500 mg/L

pH 4.8

The chemical that will be used in the chemical dosing tank for coagulation and floculation are
polyaluminum chloride (PAC) and Ferric Chloride (FeCl3). According to Rana and Suresh
(2016), FeCl3 will reduce the Chemical Oxygen Demand (COD) about 54%.

For COD removal

𝑚𝑔
𝐶𝑂𝐷 = (1 − 0.54) 𝑥 800 𝐿

𝑚𝑔
= 368 𝐿

The percentage removal for BOD and COD are 83.34% and 64.04% respectively when using
PAC. The values of pH adjusted about 6.2 to 6.9 (Solanki, Suresh, Das & Sukla, 2013).

For BOD removal,

𝑚𝑔
𝐵𝑂𝐷 = (1 − 0.8334) 𝑥 500 𝐿

𝑚𝑔
= 83.3
𝐿

For COD removal,

𝑚𝑔
𝐶𝑂𝐷 = (1 − 0.6404) 𝑥 368 𝐿

𝑚𝑔
= 132.33
𝐿

The pH will be adjusted from 4.8 to 6.5.

5
4) Clarifier

Table 3: The Initial Value of Parameters in the Inlet of Clarifier

Parameter Average value

Suspended Solid (SS) 135 mg/L

COD 132.33 mg/L

BOD 83.3 mg/L

pH 6.2

The percent removal for SS and BOD in the clarifier 40%-60% and 20-50% respectively
(EBS, 2017). The chosen removal in this case are 50% for SS and 35% for BOD.

For BOD removal,

𝑚𝑔
𝐵𝑂𝐷 = (1 − 0.35) 𝑥 83.3 𝐿

𝑚𝑔
= 54.15 𝐿

For SS removal,

𝑚𝑔
𝑆𝑆 = (1 − 0.50) 𝑥 135 𝐿

𝑚𝑔
= 67.5 𝐿

5) Sequential Batch Reactor (SBR)

Table 4: The Initial Value of Parameters in the Inlet of SBR

Parameter Average value

Suspended Solid (SS) 67.5 mg/L

COD 132.33 mg/L

BOD 54.15 mg/L

pH 6.2

6
 The percentage removal for BOD at the SBR is 85-95% (U.S EPA, 1999) while the percent
removal for COD according to Karthe is 75%.

For BOD removal,

𝑚𝑔
𝐵𝑂𝐷 = (1 − 90) 𝑥 54.15
𝐿

𝑚𝑔
= 5.415 𝐿

For COD removal,

𝑚𝑔
𝐶𝑂𝐷 = (1 − 0.75) 𝑥 132.33 𝐿

𝑚𝑔
= 33.08 𝐿

Table 5: Result for Designed Parameter that comply with standard B

Parameter Design Value Standard B

Suspended Solid (SS) 67.5 mg/L < 100 mg/L

COD 33.08 mg/L < 200 mg/L

BOD 5.415 mg/L < 50 mg/L

pH 6.2 5.5-9

7
 Summary in Flowchart Form
SS= 135 mg/L
SS= 135 mg/L SS= 135 mg/L BOD= 83.3 mg/L SS= 67.5 mg/L
3 BOD= 500 mg/L BOD= 500 mg/L COD= 132.33 mg/L BOD= 54.15 mg/L SS=16.88 mg/L
Flowrate= 2m /d
COD= 800 mg/L COD= 800 mg/L pH= 6.2 COD= 132.33 mg/L BOD= 5.415 mg/L
SS= 300 mg/L
pH= 4.8 pH= 4.8 pH= 6.2 COD= 33.08 mg/L
BOD= 500 mg/L
pH= 6.2
COD= 800 mg/L
pH= 4.8 Collection Grease Coag. Floc
Trap (FeCl3) (PAC) Clarifier Sequential
Inlet Tank
Screening Batch
Reactor
SS= 67.5 mg/L
(SBR)
BOD= 29.16 mg/L
COD= 132.33 mg/L BOD= 48.735 mg/L
COD= 99.25 mg/L

Inorganic Sludge Organic Sludge

Holder Holder

Treated Water Tank

Final Discharge to
Drain
Sludge Cake Send Filter Press 8
to Kualiti Alam
d. Design Calculation for Structure and Tanks

Collection Tank

0.3333kg/hr 0.2990kg/hr
Inlet Screen

BOD5 = 500mg/l BOD5 = 500mg/l

COD = 800mg/l COD = 800mg/l
SS = 300mg/l SS = 135mg/l

The digested sludge material was found to have a typical specific gravity of solid is 1.01
(Goncalves and Sperling, 2007). From this, we assume that pwet sludge solid is 1010 kg/m3 and the
production rate is 24 hours.

The volume of collection tank, (m3)

Volume of tank = mass flow rate (kg/hr) ÷ psludge solid x production rate

= 0.2990kg/hr ÷ 1010 kg/m3 x 24hours

= 0.007105 m3

HRT = 0.007105m3 ÷ (2m3/day x 2.5)

= 0.001421day x 24hour/day

= 0.03410hours

9
Primary Clarifier

Safety factor = 2.5

Volume Flow-rate, Q

Q = 2m3/day

Q = 2m3/day X 2.5

= 5m3/day

Assumption:

Ratio length to width is 3 :1 (L = 3w)

Depth is 3.6m (Peavy, Rowe and Tchobanoglous, 1985)

The percentage removal of suspended solid on primary clarifier is 50%. So, the overflow rate is
55m/day (Peavy, Rowe and Tchobanoglous, 1985)

Surface Area, As

m3
Q( )
day
A𝑆 = m
Overflow rate( )
day

5m3/day
A𝑆 = m
55
day

A𝑆 = 0.0909 m3

Area of primary clarifier, A

A=wXL

A = w X 3w

A = 3w2

A = 0.0909m2

3w2 = 0.0909m2

w = 0.1741m

L = 0.5222m

10
Volume of primary clarifier, V

V = area of primary clarifier (m2) X Depth (m)

= 0.09091m2 X 3.6m

= 0.3273m3

Hydraulic Retention Time, HRT

0.3274 m3
𝐻𝑅𝑇 = m3
5( )
day

= 0.06548day X (24hour/day)

= 1.5715 hours

Treated Water Tank

0.01154kg/hr
Treated Water Tank
SS =16.88 mg/L
BOD= 5.415 mg/L
COD= 33.08 mg/L

Volume of tank = mass flow rate (kg/hr) ÷ pwet sludge solid x production rate

= 0.01154kg/hr ÷ 1010 kg/m3 x 24hours

= 0.0002742 m3

HRT = 0.0001978m3 ÷ (2m3/day x 2.5)

= 0.00005484day x 24hour/day

= 0.001316hours

11
Sequence Batch Reactor, (SBR)

0.05312kg/h 0.01154kg/h
r SBR r
SS = 67.5 mg/L SS =16.88 mg/L
BOD = 54.15 mg/L BOD= 5.415 mg/L
COD = 132.33 mg/L COD= 33.08 mg/L

Volume of tank = mass flow rate (kg/hr) ÷ pwet sludge solid x production rate

= 0.05312kg/hr ÷ 1010 kg/m3 x 24hours

= 0.001262m3

HRT = 0.0009106m3 ÷ (2m3/day x 2.5)

= 0.0002524day x 24hour/day

= 0.006059hours

12
e. Design Calculation for Quantity of Chemical Sludge Production

1. The mass of primary solids and the volume of the primary sludge.

a) From the calculation mass balance, the efficiency of the clarifier is

For Suspended Solid: 50%

For BOD: 35%

b) The primary solid removed from the clarifier is found by the equation:

𝑀𝑃 = 𝜉 𝑥 𝑆𝑆 𝑥 𝑄

Where:

MP = Mass of primary solid (kg/d)

ξ = Efficiency of primary clarifier

SS = Suspended solids influent, kg/m3

Q = Flow rate m3/d

𝑚𝑔 1000 𝐿 1 𝑘𝑔 𝑚3
𝑀𝑃 = 0.5𝑥 135 𝑥 𝑥 𝑥2
𝐿 1 𝑚3 106 𝑚𝑔 𝑑

𝑘𝑔
𝑀𝑃 = 0.135 𝑑

The volume of the primary sludge is given by the equation:

MP
VP =
kg
1000 xS
m3

Where:

VP= Volume of sludge produced, m3/d

M= Mass of solid, kg/d

S= Solids content expressed as a decimal fraction (From Table

1000= Density of water

13
 From Table 5-12: Typical solids content of sludge (Peavy, Rowe& Tchobanoglous,
1985).

Taking it from unthickened primary sludge, S= 5%

0.135 𝑘𝑔/𝑑
VP =
kg
1000 x 0.05
m3

𝑚3
VP = 2.7 X 10-3
𝑑

2. The mass of secondary solid and the volume of the secondary solid from the
sequential batch reactor (SBR).

a. The mass of the secondary solids is found by the following equation:

𝑀𝑆 = 𝑌′ 𝑥 𝐵𝑂𝐷5 𝑥 𝑄

Where:

MS = Mass of secondary solids, kg/d

Y’ = Biomass conversion factor

BOD5 = BOD removed by the secondary treatment

Q = Flow rate, m3/d

According to the EPA (1999), the food to mass ratio for SBR is 0.15- 0.6/day. We
use the F: M ratio is 0.3 d-1.

From the Figure 5.37 (Peavy et. al, 1985), at F/M = 0.3, the biomass conversion factor,
Y’ = 0.38.

𝑚𝑔 𝑚𝑔
𝐵𝑂𝐷𝑖𝑛 = (1 − 0.35)𝑥 83.3 = 54.15
𝐿 𝐿

𝑚𝑔
𝐵𝑂𝐷𝑜𝑢𝑡 = 𝐵𝑂𝐷𝑒𝑓𝑓 = 5.415 𝐿

𝑚𝑔 𝑚𝑔 1000𝐿 1 𝑘𝑔
𝐵𝑂𝐷𝑐𝑜𝑛𝑠𝑢𝑚𝑒𝑑 = (54.15 − 5.415) = 48.735 𝑥 𝑥 106 𝑚𝑔
𝐿 𝐿 1𝑚3

𝑘𝑔
= 0.0487 𝑚3

𝑘𝑔 𝑚3 𝑘𝑔
𝑀𝑆 = 0.38 𝑥 0.0487 𝑥2 = 0.0370
𝑚3 𝑑 𝑑

14
 From Table 5-12: Typical solids content of sludge (Peavy, et al. 1985).

Taking it from unthickened activated sludge, S= 0.75%

0.0370 𝑘𝑔/𝑑
Vs =
kg
1000 x 0.0075
m3

𝑚3
Vs = 4.93 X 10-3
𝑑

3. The total mass of solids and the total volume of sludge to the filter press

𝑘𝑔 𝑘𝑔
𝑀𝑇 = 0.135 + 0.037
𝑑 𝑑

= 0.172 kg/d

𝑚3 𝑚3
𝑉𝑇 = 2.7 𝑥 10−3 + 4.93 𝑥 10−3
𝑑 𝑑

= 7.63 X 10-3 m3/d

4. The total mass of solid and the total volume of sludge discharge from the filter press.

The optimal solid content for filter press is 45%.

Assuming the solids in the filter press in the supernatant are neglect. The total mass
of solids in the filtered sludge is 0.172 kg/d

0.172 𝑘𝑔/𝑑
Vthick =
kg
1000 x 0.45
m3

= 3.822 x 10-4 m3/d

5. The percent of volume reduction achieved by the filter press

VT −Vthick 7.633 x 10−3 −3.822 x 10−4

x 100% = x 100%
VT 7.633 x10−3

= 95%

15
References

Agency, U. P. (1999). Wastewater Technology Fact Sheet: Sequencing Batch Reactors. EPA
932-F-99-073, 1-9.
EBS . (2017). Retrieved December, 8, 2017, from https://www.ebsbiowizard.com/primary-
clarifier-operation-667/
Goncalves, R., Luduvice, M., & Sperling, M. v. (2007). Sludge Thickening and Dewatering. In M.
v. Cleverson Vitorio Andreoli, Sludge Treatment and Disposal. (pp. 76-119). London:
IWA Publishing.
Goncalves, R. & Sperling, M. v. (2007). Sludge Characteristic and Production. In M. v.
Cleverson Vitorio Andreoli, Sludge Treatment and Disposal. (pp. 4-36). London: IWA
Publishing.
Karthe, D. (2016). Modular Concept for Municipal Waste Treatment. In J. J. DietrichBorchardt,
Integrated Water Resources Management: Concept, Research and Implementation (pp.
649-683). Springer International Publishing.
Peavy, H. S., Rowe, R. R., & Tchobanoglous, G. (1985). Enviromental Engineering. Singapore:
McGraw Hill.
Rana, S., & Suresh, S. (2017). Comparison of different Coagulants for Reduction of COD from
Textile industry wastewater. 5th International Conference of Materials Processing and
Characterization (ICMPC 2016) (pp. 567-574). India: Elsevier Ltd.
Solanki, M., Suresh, S., Das, S. N., & Shukla, K. (2013). Treatment Of Real Textile Wastewater
Using Coagulation Technology. Journal of ChemTech Research, Volume 5(2), 610-615.

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