COLLEGE OF ENGINEERING

BKC3492: SEPARATION PROCESS

MINI PROJECT: PETROCHEMICAL WASTE TREATMENT

GROUP NO. : GROUP 1

GROUP MEMBERS MATRIC ID

AMER MOHAMMED OMAR BEN GUBAER KA14186
MOHAMMED KHALED AL-SAYED KA15292
JAYAPREATHA A/P NANTAGOBALAN KA17009
SHAMALAH A/P SIVEM KA17010
MOHAMAD HATTA AIMAN BIN MOHD SALLEH KA17033

SECTION: 01G

LECTURER’S NAME: PROF ROSLI BIN MOHD YUNUS

TABLE OF CONTENTS

1.0 INTRODUCTION ........................................................................................................................ 3

1.1 Overview of the Company ........................................................................................................ 3
1.2 Manufacturing process ............................................................................................................. 4
1.3 Products ..................................................................................................................................... 7
1.3.1 Polyethylene ........................................................................................................................ 7
1.3.2 Polypropylene ..................................................................................................................... 9
1.4 Wastewater management ......................................................................................................... 9
1.5 Process Flow Diagram ............................................................................................................ 12
2.0 PROCESS DESCRIPTION .................................................................................................. 13
2.1 Description of Process Equipment ................................................................................... 14
2.2 Justification on Process Equipment ................................................................................. 15
3.0 MATERIAL & ENERGY BALANCE ...................................................................................... 19
3.1 Mass Balance ........................................................................................................................... 19
3.2 Information of Components in Each Streams ....................................................................... 28
3.3 Energy Balance ....................................................................................................................... 29
4.0 BASIC DESIGN CALCULATION AND ENGINEERING DRAWING ................................ 37
4.1 Design of Fine Screen .............................................................................................................. 37
4.2 Design of Primary Sedimentation Tank ................................................................................ 38
4.3 Design of Secondary Sedimentation Tank ............................................................................. 39
4.4 Design of Aeration Tank......................................................................................................... 40
4.5 Design of Anaerobic Digester ................................................................................................. 41
5.0 COSTING OF EQUIPMENT .................................................................................................... 42
6.0 REFERENCES............................................................................................................................ 43
7.0 APPENDIX.................................................................................................................................. 44

2
1.0 INTRODUCTION

The characteristics and volume of wastewater discharged from manufacturing factories vary
accordingly with the products and production procedures. Petrochemicals can be defined as a
large group of chemicals derived from petroleum and natural gas and used for a variety of
chemical purposes. Petrochemical plants are in the business of developing substances such as
hydrogen, carbon monoxide, synthesis gases, chemicals such as ethylene and its derivatives,
benzene and toluene to name a few. Increasing consumption of oil in modern society has led
to more oil refinery waste generation. The oil processing wastewater has high concentrations
of aliphatic and aromatic petroleum hydrocarbons. Direct discharge of the wastewater will
affect the plants and aquatic life of a surface and ground water sources. The biological treatment
process is normally applied to reduce the effects of petrochemical waste. Biological anaerobic,
anoxic and aerobic digestion (or a combination of each other) have been implemented to treat
petrochemical waste water. Optimizing pre-treatment process using physicochemical processes
is also important for getting suitable pre-treatment wastewater for efficient biological
secondary treatment.

1.1 Overview of the Company

Lotte Chemical Titan is established in 1991. It is the first standalone producer of polyolefins
and Malaysia’s largest integrated producer of olefins and polyolefins, and of the largest
polyolefins producer in Southeast Asia. Lotte Chemical Titan produces Malaysia’s most
comprehensive portfolio of olefins and polyolefins which contribute to the enhancement of
everyday life. Lotte Chemical Titan’s production site in Malaysia consists of eleven plants, two

3
co-generation plants and three tank farms. They are located on two sites in Pasir Gudang and
Tanjung Langsat in the state of Johor. Underground pipelines, shared utilities and controls
enable facilities on these sites to operate as a single integrated petrochemicals complex.
Vertical integration of olefins and polyolefins production has enabled the company to add value
and realize gains along the value chain while our customers have the assurance of consistent
quality and dependable supply. This integration facilitates higher operating rates and cushions
the impact of cyclicality. In 2006, Lotte Chemical Titan acquired PT Lotte Chemical Titan
Nusantara, Indonesia’s largest polyethylene plant in the country. This acquisition boosted the
polyethylene capacity by about 80%, thus making us one of the largest producers of polyolefin
in Southeast Asia. Lotte Chemical Titan was acquired by Lotte Chemical Corp. in 2010 and
we became one of Lotte Chemical Corp.’s largest overseas subsidiaries. Lotte Chemical Titan
Holding Berhad’s (“LCT”) strategic expansion initiative to develop an Integrated
Petrochemical Facility (“IPF”) known as the Lotte Chemical Indonesia New Ethylene Project
or the Line Project, through its subsidiary, PT Lotte Chemical Indonesia (“LCI’) is aimed to
increase the company’s production capacity and realise LCT’s vision to be a Top-Tier
Petrochemical Company in Southeast Asia by 2024.

1.2 Manufacturing process

The petrochemical industry produces various kinds of chemical products such as polymers,
fibers or rubber, from such raw materials as petroleum, LPG, natural gas and other
hydrocarbons through many different production processes. Hydrocarbons, the source material,
are used to produce a variety of components including ethylene, propylene, butadiene and
pyrolysis gasoline through non-catalytic thermal decomposition reaction with steam (steam
cracking). The feedstock for process varies depending on the availability of resources in each
country.

4
Oil exploration process consists of seven steps which are preparing the rig site, drilling,
cementing and testing, well completion, fracking, production and fracking fluid recycling
followed by well abandonment and land restoration.

Preparing the rig site

Aboveground infrastructure pads and access roads are built, setting up the land for the next
step.

Drilling

First the drill rig is brought to the location maybe 20 or 30 truck loads and put together. Now
time to build the infrastructure necessary to unlock the oil and natural gas trapped more than a
mile below the ground. A well is drilled straight down into the ground beneath the pad. The
first stage is to drill what is called the surface hole down to a depth of 100 feet below the
deepest known aquifer. A steel casing is then cemented in place so there is no risk of polluting
precious water aquifers. After this the “long hole” is drilled and after reaching a depth about
1000 feet above the underground area where oil and natural gas is trapped, the hole is
directionally steered to turn it horizontal and out maybe another mile or two in distance
following the same rock bed.

5
Cementing and testing

Once the target distance is reached, the drill pipe is removed and steel pipe is pushed to the
bottom. This “well casing” is cemented in place. Rigorous tests are performed to ensure the
pipe is impermeable before any production of natural gas or oil can occur.

Well completion

Before drillers can tap the oil and natural gas, a perforating gun is typically lowered into the
ground and fired into the rock layer in the deepest part of the well, creating holes that connect
the rock holding the oil and natural gas and the wellhead.

Fracking

Now that the first stage of the well is open, it’s time to unlock the oil and natural gas that has
been trapped in the rock. Using specialized instruments to monitor pressure and data from the
well in real time, fracking fluid, which is 99.5% water and sand and 0.5% chemicals, many of
which are found in everyday household products, is pumped at high pressure through the
perforating holes to create paper-thin cracks in the shale rock, freeing the oil and natural gas
trapped inside.

Production and fracking fluid recycling

Oil and natural gas flows up from the well bore and fracturing fluid is then recovered and
recycled and used in other fracking operations.

Well abandonment and land restoration

When all of the recovered oil and natural gas has been produced, Colorado law requires that
the well is permanently plugged and the land is returned to the way it was before the drilling
operations started. The land can then be used for other activities and there is no sign that a well
was once there.

Next, it will undergo crude distillation. Crude oil is made up of a mixture of hydrocarbons
and the distillation process aims to separate this crude oil into a broad categories of its
component hydrocarbons or fractions. Crude oil is first heated and then put into a distillation

6
column which also known as a still, where different products boil and are recovered at different
temperatures.

Then, the process will further undergoes refinery processes. Petroleum refineries change crude
oil into petroleum products for use as fuels for transportation, heating, paving roads, and
generating electricity and as feedstock for making chemicals. Refining breaks crude oil down
into its various components, which are then selectively reconfigured into new
products. Petroleum refineries are complex and expensive industrial facilities. All refineries
have three basic steps which are separation, conversion and treatment.

After that, it will undergo few unit processes to produce petrochemicals products. Chemical
plants convert oil, natural gas, air, water, metals, and minerals into chemical products.
Chemicals derived from petroleum or natural gas are known as petrochemicals which are
typically extracted during the refining process as crude oil and natural gas liquids are cracked
or distilled. Petrochemicals can be divided into two common classes: olefins (butadiene,
ethylene, and propylene) and aromatic (benzene, toluene, and xylene isomers). Oil refineries
produce olefins and aromatics by fluid catalytic cracking of petroleum fractions. Chemical
plants take natural gas liquids (ethane, propane and butane) from a gas processing plant and
use a steam cracking process to produce olefins. Aromatics are produced by catalytic reforming
of naphtha. Olefins and aromatics are the basic components for a wide range of materials such
as solvents, detergents, and adhesives. Olefins are the basis for polymers and oligomers used
in plastics, resins, fibers, elastomers, lubricants, and gels. Polymers and plastics such as
polyethylene, polypropylene, polyvinyl chloride, polyethylene terephthalate, polystyrene, and
polycarbonate make up the vast majority of the chemical industry’s output worldwide.

1.3 Products

Lotte Chemical Titan produce various products such as polyethylene, polypropylene and
derivatives of ethylene, propylene, butadiene, benzene and toluene.

1.3.1 Polyethylene

Polyethylene is the most widely-consumed thermoplastic in the world by volume. Lotte

Chemical Titan produce three types of polyethylene which name as HDPE, LDPE and LLDPE
where:

7
a) HDPE products are characterised by greater toughness and superior mechanical strength,
coupled with higher service temperature limits. HDPE is used to manufacture grocery,
merchandise and trash bags, food containers for items such as frozen desserts and margarine,
bottle caps and closures, liners for cereal and cracker boxes, plastic drink cups, dairy crates,
bread trays, pails, safety equipment such as hard hats, house wrap for insulation, bottles for
household and industrial chemicals, milk bottles, juice bottles, and large tanks for storing
liquids such as agricultural and lawn care chemicals.

b) LDPE products are easy to process and have good strength and clarity. LDPE is used to
manufacture food packaging films, plastic bottles for packaging food and personal care items,
dry cleaning bags, ice bags, pallet shrink wrap, heavy-duty bags for mulch and potting soil,
boil-in-bag bags, coatings on flexible packaging products, and coatings on paper board such as
milk cartons

c) LLDPE products offer improved strength, chemical resistance and a higher melting point,
making them suitable for high film strength applications. LLDPE is used to manufacture
garbage and lawn-leaf bags, industrial can liners, housewares, lids for coffee cans and
margarine tubs, dishpans, home plastic storage containers, kitchen trash containers, large toys
such as outdoor gym sets, drip irrigation tubing, protective coating for telephone wires and
film, shrink wrap for multi-packaging canned food, bag-in-box bags, produce bags and pallet
stretch wrap.

8
Lotte Chemical Titan produce high value added HDPE resins which are used in the production
of high quality films and high quality moldings and yarn with a melt index range from 0.05 to
30 g/10min.

1.3.2 Polypropylene
Lotte Chemical Titan polypropylene plants are configured to manufacture polypropylene
homopolymer as well as polypropylene random copolymer and impact copolymer. They offer
28 grades of polypropylene comprising 12 grades of polypropylene homopolymer and 16
grades of polypropylene random and impact copolymer. LOTTE CHEMICAL TITAN is
currently producing PP products with melt flow rate (MFR) ranging from 1.7 to 60 g/10min.
Polypropylene is a versatile polyolefin that is light-weight with high optical clarity, low
moisture vapour transmission and the ability to be drawn and oriented into fibres.
Polypropylene is used to manufacture fibres for carpets, rugs and upholstery, housewares,
automotive battery cases, running boards and bumpers, grid-type flooring for sports facilities,
fishing tackle boxes, bottle caps and closures, metallised film for food packaging, high clarity
thin walled containers and hot filled containers.

1.4 Wastewater management

Lotte Chemical Titan is an ISO14000:2004 certified organization, certified since 2011. Its
environmental management system adheres to the highest standard of environmental
compliance, based on best industry practices that are stricter than acceptable standards for the
environmental pollutants discharged from the workplace. Lotte Chemical Titan conducts
voluntary surveillance activities and ongoing environmental monitoring program for ambient

9
air, stacks, sewage, effluent and noise. Online monitoring of boiler stacks and hazardous waste
disposal are also in place by setting up an organization in charge of environmental matters in
each workplace. To ensure the systematic control of water pollutants, Lotte Chemical Titan
operates a biological wastewater treatment plant in the workplace and is effectively treating
and controlling wastewater through regular internal monitoring as well as external monitoring
by Skim Akreditasi Makmal Malaysia (SAMM) accredited laboratory. In addition, we
implement waste water reduction initiatives and look into ways to recycle wastewater.

Biological treatment

Biological treatment incorporates actions of different microbes to elimintae organics and

stabilise hazardous pollutants in petrochemical wastewater. Stringent environmental standars
and recycling of water for reuse have shifted focus to biological treatments because of its cost
and pollutant removal efficiency. As the nature of petrochemical wastewater is very complex,
biological treatment to remove pollutants still has challenges despite the immense potentials.
Examples of commonly applied biological processes to treat petrochemical wastewater such as
anaerobic digestion, aerobic digestion or an integration of both methods.Anaerobic digestion
which is applied by Lotte Titan Chemical as it has advantages such as it requires less space and
having a lower sludge regenration than aerobic process.

10
Chemical treatment

Enhancing hydrolysis by adding chemicals for removing the long-chain organics, toxic
material or suspended solids can increase the Biochemical Oxygen Demand (BOD) ratio of the
wastewater. Micro-aeration which is practiced by the company in wastewater
management.Micro-aeration breaks down high hydrocarbon content components from
wsatewater, which leads to easily biodegradable organic generation. At a dissolved oxygen
(DO) concentration from 0.2 to 0.3 mg/L, the hydrolysis of wastewater organics is enhanced.

Element Value
Wastewater volume 1000 m3/day
Biological oxygen demand (BOD) 5500 mg/L
Chemical oxygen demand (COD) 9500 mg/L
Total suspended Solid (TSS) 2200 mg/L
Sulphate 93.2 mg/L
pH 4.5

Table 1.4.1 Elements of Lotte Titan Chemical’s wastewater (Macarie et al., 1992)

11
1.5 Process Flow Diagram

Figure 1.5.1: Process flow diagram (PFD) of anaerobic waste water treatment in Lotte Titan Chemical

12
2.0 PROCESS DESCRIPTION

The process begins with raw sewage tank where sewage is pumped to the fine screen to remove
objects such as paper and plastics that may damage and clog process equipments and piping.
In this case, rotary drum fine screen is utilize. Then, the wastewater enters the sedimentation
tank for treatment purposes. This equipment enable the suspended particles in the wastewater
to settle out which provides some degree of purification. The wastewater is then sent to the
aeration tank for further treatment. In the aeration tank, oxygen is supplied to bacteria to enable
the biodegradation process. Air is also pump into the tank. This helps in treating and stabilizing
the water. The treated wastewater exits the aeration tank and enters the secondary
sedimentation tank. In this step, the BOD can decrease down to 75-80% of the influent level
and suspended solids are removed. A small volume of sludge, stream 6 is recycled back to the
aeration tank while the remaining sludge in stream 12 goes to the anaerobic digester. The sludge
is called returned activated sludge. In the anaerobic digester, anaerobic digestion takes place.
It is a process whereby microorganisms break down biodegradable material in the absence of
oxygen. During this process, biogas, mostly methane and carbon dioxide along with small
amount of water vapor and other gases are produced. These gases can be removed, leaving only
methane as methane is the primary component of natural gas. The removed gases are sent to
the gas holder. The product that is left after anaerobic digestion took place is called digestate.
Digestate is a wet mixture that is usually separated into a solid and liquid. The gas holder on
the other hand is is an important component that ensures a regular supply of biogas is available
for the rest of the plant to operate consistently and efficiently. The exiting sludge, stream 14
enters a sludge drying bed to be dewatered to reduce the volumes transported off-site. Finally,
the dried sludge is sent to the sludge tank for disposal. On the other hand, wastewater, stream
9 enters the disinfection tank where chlorine solution is injected. The effluent is then pump to
a storage tank for storage and checking purposes.

13
2.1 Description of Process Equipment

EQUIPMENTS FUNCTIONS

Coke oven wastewater that has not been

RAW SEWAGE
treated.
To remove particles that may cause
maintenance issues for process equipment
FINE SCREEN
and/or operational problems to the treatment
process.
SEDIMENTATION TANK Allow suspended particles to settle out of
water or wastewater as it flows slowly
through the tank, thereby providing some
degree of purification.
Assist aerobic microorganisms in the
consumption of pollutants by adding air because
AERATION TANK biological treatment utilize microorganisms that
naturally occur to degrade contaminants in
wastewater.
SECOND SEDIMENTATION TANK Allow the microorganisms and other solids
to settle after secondary or biological
treatment.
DISINFECTION TANK Eliminate and remove harmful organisms
completely
EFFLUENT Liquid waste or sewage is discharged to a
river or the sea (in this process it being
collected in one specific tank)
ANAEROBIC DIGESTER Allow microorganisms to break down
biodegradable material in the absence of
oxygen in order to produce biogas and
digestate.
To store biogas that is produced from
GAS HOLDER anaerobic digestion of the organic waste and
sludge

14
 Drying takes place when sludge is placed on
a bed layer by draining water through the
mass and supporting sand bed or evaporation
SLUDGE DRYING BED from the surface. Advanced drainage system
is needed for water that drains through. The
drying bed is typically partitioned into small
individual units.

SLUDGE Wastes will sink at the bottom.

2.2 Justification on Process Equipment

Raw Sewage Tank

Raw sewage tank is usually designed to last between 20 to 25 years. This type of sewage tank
is prone to rust corrosion even before reaching its 25 year lifespan. A steel sewage tank can
rust and deteriorate. So, it need to be replaced periodically without replacing the whole tank.
Sewage tanks require regular maintenance.
Fine Screen
The function of fine screen is to remove particles or objects that may damage or cause issues
to the process equipments or operational problems to the treatment process such as papers and
plastics. Fine screens are most commonly used in place of primary clarification in small
treatment facilities. Fine screens employ wire cloth, wedge wire elements or perforated plates
to remove solids in the primary effluents. The openings of fine screen range from 0.06 to 0.25
inches. Fine screens with smaller openings can remove 20 to 35% of suspended solids and
BOD.

Static wedge wire, rotary drum or step fine screens can be used depending on the situation.
Step screens is a newer technology that have fixed and movable plates to lift up the debris. The
movement of the plate provides a self-cleaning feature for this particular screen. Step screen is
also capable to form a filter mat as the trapped solids build up. The filter mat increases the
efficiency of solids removal rate of the screen. (Site, 2014) Static wedge wire screens are
typically used in industrial wastewater treatment facilities and small municipal plants. Drum
screens on the other hand can handle a large flow rate in a smaller footprint. Rotary drum
screens can either be internally or externally fed. Internally fed drum screens are capable of

15
handling higher flow rates compared to an externally fed drum screen. That is why rotary drum
fine screen is more preferable compared to the static wedge wire and step fine screens. The
rotary drum fine screen works as intercepting dregs, getting rid of dregs, spiral lifting and
pressing dewatering. It is mounted in the channel with the angles of 40˚ degrees and the
wastewater flows into the drum from the port of the drum, and the grid can intercept the dregs.
Then, the drum rotates at a fixed speed, and the nylon brush and flush water spray nozzle above
the drum can get rid of dregs will be delivered to the container or the transportation equipment.
Sedimentation Tank
Sedimentation tank enables suspended particles to settle out of water or wastewater as it slowly
flows through the tank which provides some degree of purification. A layer of accumulated
solids, called sludge, forms at the bottom of the tank and is periodically removed. In modern
sewage tank, secondary treatment (e.g., trickling filter or activated sludge) is used after the
primary sedimentation tank to increase purification efficiencies. Sedimentation is usually
preceded by treatment using bar screens and grit chambers to remove large objects and coarse solids.
(Curley, 2018). Circular sedimentation tank is preferred as it is easy to remove sludge, has high
clarification efficiency, can be used for small to medium size applications and is best suited for
plants with constant flow rates and quality. (Sedimentation Tanks).

Aeration Tank
In the aeration tank, oxygen is supplied to bacteria for treating and stabilizing the wastewater.
Bacteria needs oxygen for the process or biodegradation. Bacteria make use of the oxygen
supply in the wastewater to break down organic matter that contains carbon to form carbon
dioxide and water. If there is insufficient oxygen, bacteria cannot biodegrade the incoming
organic matter in a reasonable time. In the absence of dissolved oxygen, degradation must
occur under septic conditions which are slow, odorous, and yield incomplete conversions of
pollutants. Under septic conditions, some of the biological process convert hydrogen and
sulphur to form hydrogen sulphide and transform carbon into methane. Other carbon will be
converted to organic acids that create low pH conditions in the basin and make the water more
difficult to treat and promote odour formation. Organic matter that degrades in the absence of
oxygen is a really slow biological process. In addition, nutrients are important components in
the operation of a wastewater treatment process. Specifically, the two macronutrients nitrogen
and phosphorus, are critical building blocks for bacterial growth and reproduction, as well as
energy transfer. (Byrne, 2019).

16
Second Sedimentation Tank
The secondary sedimentation tanks or settling basins or clarifiers allow the microorganisms
and other solids to settle after secondary or biological treatment. This sludge is pumped back
into the inlet end of the primary sedimentation tanks and settles with the raw sludge. At this
stage, the BOD may be reduced to approximately 75 - 80% of the influent level and suspended
solids are removed.

Disinfection Tank
Horizontal tanks are constructed for both above-ground and underground service. Horizontal
tanks are usually made of steel with fiberglass overlay or fiberglass reinforced polyester. They
are usually constructed such that the length of the tank is not greater than six times the diameter
to ensure structural integrity. That is why horizontal tanks are generally small storage tanks.
Horizontal tanks are usually equipped with pressure-vacuum vents, gauge hatches and sample
wells, and manholes to provide accessibility to these tanks.

Anaerobic Digester
Anaerobic digestion takes place in the anaerobic digester where a sequence of processes in
which microorganisms break down biodegradable material in the absence of oxygen. During
anaerobic digestion, biogas is produced. These gases are mostly methane and carbon dioxide,
along with small amount of water vapor and other gases. Carbon dioxide and other gases can
be removed, leaving only methane. Methane is the primary component of natural gas.
“Digestate” is the term used for the material that is left after anaerobic digestion takes place. It
is a wet mixture that is usually separated into a solid and liquid. A fixed dome plant consists of
an enclosed digester with a fixed, non-movable gas space. The gas is stored in the upper part
of the digester. Slurry is displaced in the compensating tank when the production of gas begins.
Gas pressure increase with volume of gas stored, therefore if there is little gas in the holder,
the gas pressure is low. Fixed dome plants has the benefits of having low construction costs,
non-movable parts, no rusting steel parts and underground construction. (Anaerobic Digestion,
2017).

Gas Holder

Membrane gas holders are the most flexible, economical, reliable and efficient biogas storage
solution available in market. The membrane gas holder is fundamental to the process of
anaerobic digestion by ensuring a regular supply of biogas availability for the rest of the plant
to operate consistently and efficiently.

17
Sludge Drying Bed

The oldest and most commonly used type of drying bed is the conventional sand drying beds.
They are generally used for communities with populations of fewer than 20,000. There are
many possible design variations, including the layout of drainage piping, the thickness and type
of gravel and sand layers, and construction materials.

Sludge Tank

Sludge thickness is considered to decrease the volume of sludge in order to reduce the required
digester capacity. The design of thickeners (gravity, dissolved-air flotation, centrifuge, gravity
belt thickeners, rotary drum screens and others) takes into account the type and concentration
of sludge, the downstream sludge stabilization processes, dewatering and storage requirements,
the method of ultimate sludge disposal, chemical needs and the cost of operation.

18
3.0 MATERIAL & ENERGY BALANCE

3.1 Mass Balance

To find BOD, COD, TSS and Sulphate load: Biological wastewater treatment plants are
designed and operated on basis of the oxygen demand (BOD or COD) received and removed.
This is simply done by multiplying the BOD in mg/l by the daily influent volume in cubic
metres (m3). (Consultant, 2019).

Influent

5500𝑚𝑔 𝐵𝑂𝐷 1000𝑚3 1𝑥10−6 1000𝐿 5500 𝑘𝑔 𝐵𝑂𝐷

Mass of BOD = x x x =
𝐿 𝑑𝑎𝑦 1𝑚𝑔 1𝑚3 𝑑𝑎𝑦

9500𝑚𝑔 𝐶𝑂𝐷 1000𝑚3 1𝑥10−6 1000𝐿 9500𝑘𝑔 𝐶𝑂𝐷

Mass of COD = x x x =
𝐿 𝑑𝑎𝑦 1𝑚𝑔 1𝑚3 𝑑𝑎𝑦

2200 𝑚𝑔 𝑇𝑆𝑆 1000𝑚3 1𝑥10−6 1000𝐿 2200 𝑘𝑔 𝑇𝑆𝑆

Mass of TSS = x x x =
𝐿 𝑑𝑎𝑦 1𝑚𝑔 1𝑚3 𝑑𝑎𝑦

93.2 𝑚𝑔 𝑆𝑢𝑙𝑝ℎ𝑎𝑡𝑒 1000𝑚3 1𝑥10−6 1000𝐿 93.2 𝑘𝑔 𝑆𝑢𝑙𝑝ℎ𝑎𝑡𝑒

Mass of Sulphate = x x x =
𝐿 𝑑𝑎𝑦 1𝑚𝑔 1𝑚3 𝑑𝑎𝑦

Component S1
BOD 5500 kg/day
COD 9500 kg/day
TSS 2200 kg/day
S 93.2 kg/day

19
Stream 1 (S1)

The components from the wastewater tank enter the stream 1.

Component S1
BOD 5500 kg/day
COD 9500 kg/day
TSS 2200 kg/day
S 93.2 kg/day

Stream 2 (S2)

Component S2
BOD 5500 kg/day
COD 9500 kg/day
TSS 2200 kg/day
S 93.2 kg/day

20
Stream 3 (S3)

Screening is the first unit operation used at wastewater treatment plants (WWTPs). Screening
removes objects such as rags, paper, plastics, and metals to prevent damage and clogging of
downstream equipment, piping, and appurtenances. Assume all components are removed by
20% in screening tank.

BOD load = 5500 − 0.2(5500) = 4400 kg/day

COD load = 9500 − 0.2(9500) = 7600 kg/day

TSS load = 2200 − 0.2(2200) = 1760 kg/day

Sulphate load = 93.2 − 0.2(93.2) = 74.56 kg/day

Component S3
BOD 4400 kg/day
COD 7600 kg/day
TSS 1760 kg/day
S 74.56 kg/day

Stream 4 (S4)

21
The primary sedimentation tank is designed to reduce the velocity of the wastewater flow,
allowing heavier organic solids (called raw sludge) to settle. They are the first stage of
treatment after the removal of rags and grit in the inlet works.

Assume 35% BOD is removed,

BOD load = 4400 − 0.35(4400) = 2860 kg/day

Assume 60% COD is removed,

COD load = 7600 − 0.6(7600) = 3040 kg/day

Assume 60% TSS is removed,

TSS load = 1760 − 0.6(1760) = 704 kg/day

Assume 75% Sulphate is removed,

Sulphate load = 74.56 − 0.75(74.56) = 18.64 kg/day

Component S4
BOD 2860 kg/day
COD 3040 kg/day
TSS 704 kg/day
S 18.64 kg/day

Stream 5 (S5)

Aeration tank is the most critical and crucial component of a treatment system using the
activated sludge process. A well-designed aeration system has a direct impact on the level of
wastewater treatment it achieves. Air is blow into aeration tank for better process.

22
Assume 55% BOD is removed,

BOD load = 2860 − 0.55(2860) = 1287 kg/day

Assume 77% TSS is removed,

TSS load = 704 – 0.77(704) = 161.92 kg/day

Assume 66.72% Sulphate is removed,

Sulphate load = 18.64 – 0.6672(18.64) = 6.2034 kg/day

Assume COD is not removed in the aeration process.

Component S5
BOD 1287 kg/day
COD 3040 kg/day
TSS 161.92 kg/day
S 6.2034 kg/day

Stream 6 (S6) & Stream 7 (S7)

Stream 6 and Stream 7 usually 30% of sludge is recycled back to the aeration tank. Therefore,
70% of sludge goes to anaerobic digester. The sludge is called returned activated sludge. The
settled activated sludge that is collected in a secondary clarifier and returned to the secondary
treatment process to mix with incoming wastewater. This returns a concentrated population
of microorganisms back into the aeration basin.

TSS = 56.672 kg/day

23
Sulphate = 0.1674918 kg/day

In stream 6 & stream 7

TSS = 0.3(56.672) = 17.002 kg/day

Sulphate = 0.3(0.1674918) = 0.05024754 kg/day

Component S6 & S7
BOD -
COD -
TSS 17.002 kg/day
S 0.05024754 kg/day

Stream 9 (S9)

Secondary sedimentation tank allows suspended particles to settle out of water or wastewater
as it flows slowly through the tank, thereby providing some degree of purification. A layer of
accumulated solids, called sludge, forms at the bottom of a tank and is periodically removed.

At this stage, the BOD may be reduced to approximately 75 - 80% of the influent level and
suspended solids are removed.

Assume BOD is removed by 80%,

BOD load = 1287 − 0.8(1287) = 257.4 kg/day

Assume sulphate is removed at 97%,

Sulphate load = 6.2034 − 0.97(6.2034) = 0.186102 kg/day

Assume 1% of Sulphate stay as an effluent, the remaining will go to the sludge,

Sulphate solution remained to disinfection tank = 0.1(0.186102) = 0.0186102 kg/day

Sulphate to the sludge = 0.186102 - 0.0186102 = 0.1674918 kg/day

All suspended solids (TSS) are removed to the sludge and 65% is removed,

TSS in sludge = 161.92 − 0.65(161.92) = 56.672 kg/day

Assume COD is removed by 85.3%, COD load = 3040 − 0.853(3040) = 446.88 kg/day

24
 Component S9
BOD 257.4 kg/day
COD 446.88 kg/day
TSS -
S 0.0186102 kg/day

Stream 10

Disinfection normally involves the injection of a chlorine solution at the head end of a chlorine
contact basin. The chlorine dosage depends upon the strength of the wastewater and other
factors, but dosages of 5 to 15 mg/l are common. After disinfection or known as chlorination,
components are pump to store in the storage tank and undergo checking process.

Assume COD is removed at 39%,

COD load = 446.88 – 0.39(446.88) = 272.597 kg/day

Assume BOD is removed at 46%,

BOD load = 257.4 – 0.46(257.4) = 138.996 kg/day

Assume there is no change in composition of Sulphate in disinfection tank;

S = 0.0186102 kg/day

Component S10
BOD 138.996 kg/day
COD 272.597 kg/day
TSS -
S 0.0186102 kg/day

25
Stream 11

Component S11
BOD 138.996 kg/day
COD 272.597 kg/day
TSS -
S 0.0186102 kg/day

Assume that 95% of the influent will be removed as effluent,

Effluent = 0.95(1000) = 950 m3 /day

Stream 12, Stream 14, Stream 15

Stream 12

Component S12
BOD 257.4 kg/day
COD 446.88 kg/day
TSS -
S 0.0186102 kg/day

26
Stream 14

Assume COD is removed at 96%,

COD load = 446.88 – 0.96(446.88) = 17.8752 kg/day

Assume BOD is removed at 96%,

BOD load = 257.4 – 0.96(257.4) = 10.296 kg/day

Component S14
BOD 10.296 kg/day
COD 17.8752 kg/day
TSS 161.92 kg/day
S 0.0186102 kg/day

Stream 15

Component S14
BOD 10.296 kg/day
COD 17.8752 kg/day
TSS 56.672 kg/day
S 0.1674198 kg/day

27
3.2 Information of Components in Each Streams

COMPONENTS (kg/day) S1 S2 S3 S4
BOD 5500 5500 4400 2860
COD 9500 9500 7600 3040
TSS 2200 2200 1760 704
S 93.2 93.2 74.56 18.64

COMPONENTS (kg/day) S5 S6 S7 S9
BOD 1287 1287 1287 257.4
COD 3040 3040 3040 446.88
TSS 161.92 17.002 17.002 161.92
S 6.2034 0.05024754 0.05024754 0.0186102

COMPONENTS (kg/day) S10 S11 S12 S14

BOD 138.996 138.996 257.4 10.296
COD 272.597 272.597 446.88 17.8752
TSS 161.92 161.92 161.92 161.92
S 0.0186102 0.0186102 0.0186102 0.0186102

COMPONENTS (kg/day) S15

BOD 10.296
COD 17.8752
TSS 56.672
S 0.1674198

28
3.3 Energy Balance

Most of the equipment needed the electricity to perform its function, such as pump, fine screen,
aeration tank agitator, peripheral rotating bridge circular scraper in primary sedimentation tank
and secondary sedimentation tank, and dual fuel motor. Below shows the energy balance
required in the design of the wastewater treatment plant for that important equipment.

For the wastewater treatment process, three pumps are needed to move the liquid from the start
of the effluent from industry to the end of clean water which can be discharged in the entire
process. So, in order to move the fluid, the pump power is needed to drive the fan or compressor
in the pump. Few factors like pump and motor performance, differential pressure, fluid density,
viscosity, and flow rate influence the power needed by the pump.

A few assumptions are done before calculating the power and energy consumed.

Assumption:

• The pump function in isothermal condition

• No air was present in the pump

• The differential head for all the pumps involve are standardized to 5m each

• Density of water, 𝜌𝐻2𝑂 is 1000kg/m3

• Gravitational acceleration constant, g = 9.81m/s2

• The pump efficiency is assumed to be 85%, = 0.85

• The motor efficiency is assumed to be 90%, = 0.9

PUMP 1

1000𝑚3 1 𝑑𝑎𝑦 1 ℎ𝑜𝑢𝑟 1 𝑚𝑖𝑛 0.0116𝑚3

Volumetric flow rate, Q (m3/day) = x x x =
𝑑𝑎𝑦 24 ℎ𝑜𝑢𝑟𝑠 60 𝑚𝑖𝑛 60 𝑠 𝑠

29
 1000 𝑘𝑔 9.81 𝑚
The differential pressure, ∆P = ρ g ∆h = x x 5m = 49050 Pa = 49050 Nm2
𝑚3 𝑠2

Theoretical power requirement, P theorectical = Q x ∆P

0.0116𝑚3
= x 49050 Nm2
𝑠

= 568.98 W

= 0.56898 kW

𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑝𝑜𝑤𝑒𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡,𝑃𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙

Pump shaft power requirement, P shaft = 𝑝𝑢𝑚𝑝 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

0.56898 𝑘𝑊
= 0.85

= 0.6694 kW

𝑝𝑢𝑚𝑝 𝑠ℎ𝑎𝑓𝑡 𝑝𝑜𝑤𝑒𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡,𝑃𝑠ℎ𝑎𝑓𝑡

Motor power requirement, P motor = 𝑚𝑜𝑡𝑜𝑟 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

0.6694 𝑘𝑊
=
0.9

= 0.7438 kW HP

1.3596 𝐻𝑃
= 0.7438 kW x = 1.0113 HP
𝑘𝑊

PUMP 2

950𝑚3 1 𝑑𝑎𝑦 1 ℎ𝑜𝑢𝑟 1 𝑚𝑖𝑛 0.0110𝑚3

Volumetric flow rate, Q (m3/day) = x x x =
𝑑𝑎𝑦 24 ℎ𝑜𝑢𝑟𝑠 60 𝑚𝑖𝑛 60 𝑠 𝑠

1000 𝑘𝑔 9.81 𝑚
The differential pressure, ∆P = ρ g ∆h = x x 5m = 49050 Pa = 49050 Nm2
𝑚3 𝑠2

Theoretical power requirement, P theorectical = Q x ∆P

0.0110
= x 49050 Nm2
𝑠

= 539.55 W

30
 = 0.53955 kW

𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑝𝑜𝑤𝑒𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡,𝑃𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙

Pump shaft power requirement, P shaft = 𝑝𝑢𝑚𝑝 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

0.53955 𝑘𝑊
= 0.85

= 0.63476 kW

𝑝𝑢𝑚𝑝 𝑠ℎ𝑎𝑓𝑡 𝑝𝑜𝑤𝑒𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡,𝑃𝑠ℎ𝑎𝑓𝑡

Motor power requirement, P motor = 𝑚𝑜𝑡𝑜𝑟 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

0.63476 𝑘𝑊
= 0.9

= 0.70529 kW HP

1.3596 𝐻𝑃
= 0.70529 kW x 𝑘𝑊
= 0.9589 HP

PUMP 3

604 𝑚3 1 𝑑𝑎𝑦 1 ℎ𝑜𝑢𝑟 1 𝑚𝑖𝑛 0.006711 𝑚3

Volumetric flow rate, Q (m3/day) = x x x =
𝑑𝑎𝑦 24 ℎ𝑜𝑢𝑟𝑠 60 𝑚𝑖𝑛 60 𝑠 𝑠

1000 𝑘𝑔 9.81 𝑚
The differential pressure, ∆P = ρ g ∆h = x x 5m = 49050 Pa = 49050 Nm2
𝑚3 𝑠2

Theoretical power requirement, P theorectical = Q x ∆P

0.006711
= x 49050 Nm2
𝑠

= 329.175 W

= 0.329175 kW

𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑝𝑜𝑤𝑒𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡,𝑃𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙

Pump shaft power requirement, P shaft = 𝑝𝑢𝑚𝑝 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

0.329175 𝑘𝑊
= 0.85

31
 = 0.38726 kW

𝑝𝑢𝑚𝑝 𝑠ℎ𝑎𝑓𝑡 𝑝𝑜𝑤𝑒𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡,𝑃𝑠ℎ𝑎𝑓𝑡

Motor power requirement, P motor =
𝑚𝑜𝑡𝑜𝑟 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

0.38726 𝑘𝑊
= 0.9

= 0.43029 kW HP

1.3596 𝐻𝑃
= 0.43029 kW x = 0.58502 HP
𝑘𝑊

FINE SCREEN

The fine screen consists of only one moving part. One machine with a single motor to screen,
wash, compact, and dewater the debris from wastewater. For the fine screen we calculate the
pressure loss and relate it to the power consumption.

Assumption:

• It functions in isothermal condition

• Empirical discharge coefficient, C = 0.7

• Density of water, 𝜌𝐻2𝑂 is 1000kg/m3

• Density of suspended solid, 𝜌 total 𝑠𝑢𝑠𝑒𝑛𝑑𝑒𝑑 𝑠𝑜𝑙𝑖𝑑 = 593kg/m3

• Gravitational acceleration constant, g = 9.81m/s2

• Assume effective open area of submerged screen is 0.009m

• Assume motor efficiency to be 90%

Total mass of the substances = (1000 x 1000) + 5500 + 9500 + 2200 + 93.2 = 1017293.2 kg/h

(1000 𝑥 1000)
Composition of liquid = = 0.98
1017293.2

32
Total density = 0.02(593) + 0.96(1000) = 971.86 kg/m3

1000𝑚3 1 𝑑𝑎𝑦 1 ℎ𝑜𝑢𝑟 1 𝑚𝑖𝑛 0.0116𝑚3

Q= x x x =
𝑑𝑎𝑦 24 ℎ𝑜𝑢𝑟𝑠 60 𝑚𝑖𝑛 60 𝑠 𝑠

1 𝑄
h L = 2𝑐𝑔 x (𝐴)2

1 0.0116
= 2(0.7)(9.81) 𝑥 ( 0.009 )2

= 0.121 m

Potential energy, P = 𝑚𝑔∆h = 971.86 kg/m3 x 0.0116 m3/s x 9.81m/s2 x 0.121m

= 13.382 N

𝑝𝑜𝑡𝑒𝑛𝑡𝑖𝑎𝑙 𝑒𝑛𝑒𝑟𝑔𝑦 13,382 𝑁

Power = = = 13.382 W
𝑡𝑖𝑚𝑒 1𝑠

AERATION TANK

With the exist of this mixer of aeration tank, it keeps all settled solids uniformly suspended
and off the tank floor for maximum which will enhance the mixing and homogenization of
liquids.

Assumption:

• It functions in isothermal condition

• Marine propeller

• The differential head for all the pumps involve are standardized to 5m each

• Density of water, 𝜌𝐻2𝑂 is 1000kg/m3

• Assume stirred speed, V = 4 ms-1

33
• Assume viscosity of fluid, μ = 0. 004pa.s

• Assume diameter of the tank = 41.2 m

𝑣𝑑2 ρ
Reynold number, N Re = μ

(4)(41.2)2 (1000)
= 0.004

= 1.70x109 which is more than 2100, so it is consider as turbulent flow.

From the figure, 𝑁𝑃 ′ = 1.56

Therefore, P= 1.56 x 1000 x 43 x 41.25 = 1.1852x1013 kgm2S -3 = 11.8520 TW

34
PRIMARY SEDIMENTATION TANK

Assumption:

• It functions in isothermal condition

• The differential head for all the pumps involve are standardized to 5m each

• Density of water, 𝜌𝐻2𝑂 is 1000kg/m3

• Assume scrapers peripheral speed = 2.5 rpm

• Assume slow shaft rpm= 0.05

• Assume diameter of the tank = 29.08 m

4400 𝑘𝑔 1
• Assume load on the scrapers per linear metre, K = x 29.08 𝑚 = 151.307 kg/m
𝑑𝑎𝑦

Torque, 𝜏 = r2 x K

= (29.08 m)2 x 151.307 kg/m = 127952.2198 kg. m

To transmit the torque with 127952.2198 kg. m in each second,

𝑝𝑜𝑤𝑒𝑟(𝐻𝑃)𝑥 9550
Torque = 𝑠𝑝𝑒𝑒𝑑 𝑖𝑛 𝑅𝑃𝑀

𝑇𝑜𝑟𝑞𝑢𝑒 𝑥 𝑠𝑝𝑒𝑒𝑑 𝑖𝑛 𝑅𝑃𝑀

Power (HP) =
9550

127952.2198 𝑘𝑔.𝑚 𝑥 0.047 𝑟𝑝𝑚

Power (HP) =
9550

= 0.6297 HP kW

0.7457 𝑘𝑊
= 0.6297 HP x 1 𝐻𝑃

= 0.4696 kW

35
SECONDARY SEDIMENTION TANK

Assumption:

• It functions in isothermal condition

• The differential head for all the pumps involve are standardized to 5m each

• Density of water, 𝜌𝐻2𝑂 is 1000kg/m3

• Assume scrapers peripheral speed = 2.5 rpm

• Assume slow shaft rpm= 0.05

• Assume diameter of the tank = 36.78 m

1287 𝑘𝑔 1
• Assume load on the scrapers per linear metre, K = x 36.78 𝑚 = 34.99 kg/m
𝑑𝑎𝑦

Torque, 𝜏 = r2 x K

= (36.78 m)2 x 34.99 kg/m = 47333.37 kg. m

To transmit the torque with 47333.37 kg. m in each second,

𝑝𝑜𝑤𝑒𝑟(𝐻𝑃)𝑥 9550
Torque = 𝑠𝑝𝑒𝑒𝑑 𝑖𝑛 𝑅𝑃𝑀

𝑇𝑜𝑟𝑞𝑢𝑒 𝑥 𝑠𝑝𝑒𝑒𝑑 𝑖𝑛 𝑅𝑃𝑀

Power (HP) =
9550

47333.37 𝑘𝑔.𝑚 𝑥 0.047 𝑟𝑝𝑚

Power (HP) = 9550

= 0.23295 HP kW

0.7457 𝑘𝑊
= 0.6297 HP x 1 𝐻𝑃

= 0.17371 kW

36
4.0 BASIC DESIGN CALCULATION AND ENGINEERING DRAWING
4.1 Design of Fine Screen
Design Flow = 1000 m3/day

At average flow design velocity = 0.8 m/s = 69120 m/day

1000 𝑚3/𝑑𝑎𝑦
Area required = 69120 𝑚/𝑑𝑎𝑦 = 0.01447 m2

Side Water Depth (SWD) = 0.8 m

At peak design velocity = 1.6 m/s

Assuming the screen bars are placed at 40o to the horizontal,

Clear area = 0.01447 x (1.6 sin 40) = 0.01487 m2

Clear Opening = 8mm = 0.008m

0.01487 𝑚2
Net Clear Width of Channel = 0.008 𝑚
= 1.8599m

Number of Clear Openings = 178

Number of bars = 178

Size of the bars = 50mm x 10mm

(178𝑥8) (178𝑥10)
Width of channel = + = 3.2m
1000 1000

Fine Screen is designed for the size of 3.2m x 0.8m (SWD) x 0.5 (FB)

Figure 4.1: Cross-section of disc type Fine Screen.

37
4.2 Design of Primary Sedimentation Tank
Maximum Quantity Sewage = 26.56 MLD = 26560m3/day

40𝑚3
Surface Loading Rate = 𝑚2 . 𝑑𝑎𝑦

Detention Time = 1 hour = 0.04167 day

26560m3/day
Volume of Sewage = = 1106.7m3
24

Provide Effective Depth = 2.5m

1106.7𝑚3
Surface Area = = 442.68m2
2.5𝑚

Surface Area of the Tank = Total Flow Surface Loading

26560𝑚3
= = 664m2
40𝑚3

Use the greater value of these two. ⸫ The surface areas of the tank = 664m2

4×664𝑚2
Diameter of the Tank = √ = 29.08m
𝜋

Primary Sedimentation Tank is designed for the dimension of

29.08m (diameter) x 2.5m (depth) x 0.5 (FB)

0.5m
29.08m
m
2.5m
0.5m

Figure 4.2: Cross-section of a Primary Sedimentation Tank

38
4.3 Design of Secondary Sedimentation Tank
Number of secondary clarifiers = 1

Average Flow = 26.56 MLD = 26560m3/day

Recirculated Flow = 50% x 26560m3/day = 13280m3/day

Total Inflow = (26560 + 13280) m3/day = 39840 m3/day

Provide Hydraulic Detention Period = 2 hours = 0.0833 day

39840𝑚3
×2
𝑑𝑎𝑦
Volume of Tank = = 3320 m3
24

Assume Liquid Depth = 3.5m

3320𝑚3
Area = 3.5𝑚
= 948.57m2

25𝑚3
Surface Loading = 𝑚2 . 𝑑𝑎𝑦

26560𝑚3 /𝑑𝑎𝑦
Surface Area = 25𝑚3
= 1062.4m2
𝑚2 . 𝑑𝑎𝑦

Use the greater value of these two, ⸫the surface areas of the tank = 1062.4m2

4×1062.4𝑚2
Diameter of the Tank = √ = 36.78m
𝜋

Primary sedimentation tank is designed for the dimension of

36.78m (diameter) x 3.5m (depth) x 0.5 (FB)

0.5m
36.78m

3.5m

Figure 4.3: Cross-section of Secondary Sedimentation Tank

39
4.4 Design of Aeration Tank
Number of Aeration Tank = 1
Design Flow, Q = 950m3/day

BOD at inlet = 2860kg/day = 3.01kg/m3 = 3011mg/l

BOD at outlet = 1287kg/day = 1.3547kg/m3 = 1355mg/l

3011𝑚𝑔 1355𝑚𝑔
−
𝑙 𝑙
Minimum Efficiency = 3011𝑚𝑔 x 100% = 54.99%
𝑙

MLSS (Xt) = 5000mg/l

F/M ratio = 0.5

3011𝑚𝑔 1355𝑚𝑔
𝑄 ×𝐵𝑂𝐷𝑟𝑒𝑚𝑜𝑣𝑒𝑑 950𝑚3 ×( − )
𝑙 𝑙
Volume of The Tank Required = 𝐹 = = 629.28m3
( )×𝑋𝑡 0.5 ×5000𝑚𝑔/𝑙
𝑀

Assume the liquid depth of the tank is 4.5m.

Width: Depth

3:1

Since the depth of the tank is 4.5m, the width of the tank is 13.5m.

𝑉𝑜𝑙𝑢𝑚𝑒 629.28𝑚3
Length = 𝑊𝑖𝑑𝑡ℎ ×𝐷𝑒𝑝𝑡ℎ = 13.4𝑚 ×4.5𝑚 =10.44m

Aeration tank is designed for the dimension of 10.44m(length) x 13.5m(width) x 4.5m(depth)

Figure 4.4: Cross-sectional of Aeration Tank

40
4.5 Design of Anaerobic Digester
Sd Substrate Input Quantity = 4.75m3/day

RT Rentation Time = 7.8 days

V = Sd x RT

V = 4.75 m3/day x 7.8 days

V = 37.05m3

Height / Diameter = 2

𝑉×4 37.05 × 4
DTank = 𝐻
1 = 1 = 80.3270m
(3.14 × )3 (3.14 × 2)3
𝐷

Height = 2 x Dimeter

Height = 2 x 80.3270 m

Height = 160.654 m

41
5.0 COSTING OF EQUIPMENT

Equipment Cost($)
Raw Sewage Tank 2000.00
Fine Screen 20000.00
Sedimentation Tank 21751.00
Aeration Tank 25000.00
Secondary sedimentation Tank 19000.00
Disinfection Tank 6000.00
Centrifugal Pump ( 4 units) 6000.00
Anaerobic digester 70000.00
Sludge Drying Bed 50000.00
Sludge Tank 9500.00
Total 229251.00

Table 5.1: Costing of equipments Lotte Titan Chemicals waste treatment (Alibaba, n.d.)

𝑅𝑀 4.25
𝐶𝑜𝑠𝑡𝑖𝑛𝑔 (𝑅𝑀) = $ 229251.00 × = 𝑅𝑀 974316.75
1$

42
6.0 REFERENCES

Alibaba. (n.d.).
https://www.alibaba.com/?spm=a27aq.14153049.scGlobalHomeHeader.4.42bb7b26HmYhUb

Macarie, H., Noyola, A., & Guyot, J. P. (1992). Anaerobic treatment of a petrochemical
wastewater from a terephthalic acid plant. Water Science and Technology, 25(7), 223–
235. https://doi.org/10.2166/wst.1992.0154

Centrifugal Pump: Working Principle, Different Types, and Applications. (2019, June 21). Retrieved
July 28, 2019, from ElProCus - Electronic Projects for Engineering Students website:
https://www.elprocus.com/centrifugal-pumps-working-types-and-applications/

Storage tanks, Fixed-roof tanks, Floating roof tanks, Spherical Storage Vessel (Spheres), Pressure
tanks, LNG (Liquefied Natural Gas) tanks. (2019). Retrieved December 17, 2019, from
Wermac.org website: http://wermac.org/equipment/storage_tanks_vessels_general.html

Membrane Type Gas Holder | GGE Power Pvt. Ltd. (2019). Retrieved December 17, 2019, from
Ggepower.com website: https://www.ggepower.com/web/membrane-type-gas-holder/
Lemmons, R. (2019, December 11).

Drying Beds - Wastewater Sludge - Climate Policy Watcher. Retrieved from Climate Policy Watcher
website: https://www.climate-policywatcher.org/wastewater-sludge/drying-beds.html

The Water Treatments. (2010, December 29). Type of Activated Sludge Process. Retrieved December
17, 2019, from Water Treatment | Waste Water Treatment | Water Treatment Process & Plant
Design website: http://www.thewatertreatments.com/wastewater-sewagetreatment/type-
activated-sludge-process/

Types of Screening in Wastewater Treatment | Wastewater Screening. (2018, March 20). Retrieved
December 17, 2019, from AOS Treatment Solutions website: https://aosts.com/types-
wastewater-screening/ The Constructor. (2016, December 4).

Types of Sedimentation Tanks used in Water Treatment. Retrieved November 9, 2019, from The
Constructor website: https://theconstructor.org/environmental-engg/types-of-sedimentation-
tank/14711/

43
7.0 APPENDIX

44
45
46