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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
71.2
3.6
6.4
2.9
3.3
4.6
92
71.2
15
45
22
15.5
15.5
191.2
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.
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
35
35
35
35
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
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
1.0
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
1.2
~100 ppm
~50 ppm
~110 ppm as CaCO3
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
2.2
2.3
2.4
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.
3.2
Process Outline
3.2.1
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
3.2.8
3.2.9
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
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.
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.