WASTE WATER TREATMENT PLANT IN ECOTEX INNOVATION WITH SEQUENCING BATCH REACTOR (SBR)

MD. SAIDUR RAHMAN SAJIB T.T.H Pre-Registation No. 1651 Supervised By : Dr. Zulhas Ahmed signature : .

Head Of The Department of Wet Processing College Of Textile Engineering & Technology(CTET)

Abstract:

There are a lot of technology involve with waste water treatment. Ecotex is a

composite textile mill which is using the latest technology to treat their waste water. This paper work considers the study of sequencing Batch Reactor (SBR) in waste water treatment plant. For this purpose , Ecotex is taken for study. This report also contain a short description of the various Hi-Tec process module involved with Ecotex wastewater treatment plant such as equalization tank, coagulation, flocculation, Ozonation, , extended aeration, sequencing batch reactor e.t.c . The feasibility of bench scale sequencing batch reactors (SBRs) in treating in Ecotex effluent is demonstrated at various influent chemical oxygen demands (CODs) ranging from 300 to over 4,000 mg/L. The SBRs removed over 75% of the biodegradable fraction of the influent COD at a fixed react time of 5.5 h. An easy to use process model is presented to predict the temporal variations of substrate, biomass, and dissolved oxygen concentrations during the fill and react

periods in SBRs. The model satisfactorily predicted effluent COD and final biomass concentrations, as well as temporal variations of COD, biomass, and dissolved oxygen throughout the fill and react cycles. The study provides a user-friendly approach to access essential knowledge about SBR and the procedures to design SBR, including design requirements, facilities selection and its advantage or disadvantage . it also describe the latest Ozonator technology which is Used By Ecotex . The paper concludes that the result of SBR technology involved with Ecotex by some spreadsheet calculation. Keywords : Sequencing batch reactor(SBR) , Activated sludge , COD, BOD . Introduction The textile industry occupies an important place in the economy of Bangladesh and water and chemicals for various operations like washing, dyeing, etc. The low other developing countries. Textile

processing consumes enormous quantity of a fully automated control wet processing floor where a hue amount of water is used per day . the waste water is discharged through the waste water treatment plant pipe Into their plant . every day they discharge

efficiency of chemical operations and spillage of chemical cause, a significant pollution hazard and make the treatment of discharged wastewater a complex problem.

average 850 m3/day water . The water Most of the wastewater treatment plants recently adopt methods of chemical parameter just before entering the treatment plant are very high but after treatment this parameter comes down near to the drinking quality !! Actually they are using the repetition of chemical precipitation and

precipitation and subsequent clarification. Ecotex is a fully automated company situated in the Chandra,Pollibydut,Gazipur. It is a Uk-Bangladesh joint venture

company. It is a composite mill which have

subsequent clarification. On the other hand,

for using the SBR technology with latest ozonator technology they treat the water like this . The initial COD value is over 300 mg/L but after treatment it comes down average of 5 mg/L . This is a waste water treatment plant which are using the physicochemical method. This treatment plant is designed for treatment of 15 ton water per day . the cost of treating water is 15 BDT / m3 . The BOD and COD value of the water is reduced because of the double chemical action . For this reason the water parameter after treatment is so good for the Ecotex . The water characteristics , Design criteria and constraints used in ecotex is given below

Table 1 : water characteristics , constrains used in Ecotex ( provided by Ecotex ) Parameters Effluent BOD5 Influent flow rate, Q Influent suspended solids, SSin Influent volatile suspended solids, VSSin Wastewater temperature Influent BOD5 for each day Hydraulic detention time, Food-to-microorganism ratio, F/M MLVSS/MLSS Kinetic coefficients: Biomass yield, Y Endogenous decay coefficient, kd Average concentration of settled sludge Settled sludge specific gravity Percent of the reactor volume which will be decanted each day Liquid depth of SBR Sludge wasting per week Biological solids in effluent Percent of biodegradable in effluent Unit mg/l Mgal/d mg/l mg/l
o

C mg/l h

lb/lb
-1

d mg/l

ft

mg/l %

Methodology Plant layout Ecotex having the great design to treat water fully and eco-friendly . the total plant is divided into two part. One part for chemical treatment and another part is for biological treatment . these two combination makes Ecotex wastewater treatment plant more cost effective .

A typical flow diagram of this plant is given below -

Raw water.

Manual + Mechanical Screen

Equalisation tank

Ozone contact tank 1

Flocculation tank 1

Ozone

coagulant & polymer Clarifier 1

Flocculation tank 2

Ozone contact

Intermediate tank

tank 2
Clarifier 2 Water discharge

Sequence batch reactor

supernant

through drain

Aerobic digester tank

Filter press

Sludge disposal

Figure 1 : Process flow sheet of waste water treatment plant in Ecotex .

Process Description The various section of waste water treatment plant in Ecotex is given below shortly
Screening & Equalization

manual Bar screen and another Mechanical bar screen which is the product of Herman

Screens are very simple materials having iron bars in the form of square grids. Effluent is allowed to pass through the grid when large and coarse solid materials are arrested by it allowing smaller particles and effluent to pass through. In some several grids are use with diminishing grid sizes. In Ecotex they are using two screen ,one

company .

Figure : Mechanical Bar Screen Equalization tank is a large chamber which is designed for retention time . The

equalization tank is specially built where air is blown by two blowers alternately round the clock on continuous basis. The purposes of equalization are to supply oxygen so that DO level increases and To mix various types effluents and To reduce the temperature of the Water .In Ecotex they are using blower provided by SSR blower

method . this oxygen then goes into the ozone contact tank where the oxygen is mixed with the waste water

. Figure: Ozone machine in ecotex In Ecotex there are 16 ozonator machine . this machines are patented under the Mark 5 , Nuvo . The 8 m/c is used for ozone contact tank 1 , and another 8 m/c is used for ozone contact tank 2 .

. Figure : Equalization tank in Ecotex

Ozonation for ozone contact tank

The reaction for ozonator is given below -

Ozone technology is the latest technology for wastewater treatment plant . In this system the Air is purified into the Oxygen . the machine which is used for ozone technology is known as ozonator . This ozonator machine is worked as they took the air as their input and they mixed it with the water separate the ozone , which is being converted into the oxygen by spark

Ozone

(spark method)

oxygen

The oxygen is carried out from the ozonator to the tank by the pump and diffused through the diffuser . The ozone technology is one of the greatest technology nowadays . it makes the water more soften.
Flocculation And Coagulation

From the ozone contact tank the effluent is taken to a small tank which is also called

flash mixing tank of small retention time. In the flash-mixing tank coagulants like lime (Ca(OH)2) and flocculants like ferrous sulfate (FeSO4) are dosed. This is done for coagulation and removal of the total dye particles. The basic idea of adding coagulant is to bring together all the suspended and dye particles so that they can be precipitated out in the flash mixing tank and flocculation tank by coagulation and flocculation

Adequate

quantity

of

poly-electrolyte

polymer solution is dosed in the flocculation tank followed by flash mixing tank to enhance the process of color removal by the flocculation process. A substantial amount BOD and COD etc. are re-moved in the coagulation and flocculation process.

mechanism. The chemical re-action that occurs in the coagulation and flocculation process is shown be-low; Figure : Flocculator tank CaO + H2O = Ca(OH)2 In Ecotex there are two flocculator tank . The above reaction take place in flash One being use after ozone tank 1 and mixing tank when lime reacts with water another one is used after ozone tank 2 . and we get calcium hy-droxide solution. This solution reacts with the ferrous sulfate solution, which as followsClarifier is the big tank where the sludge is Ca(OH)2 + FeSO4 = CaSO4 + Fe(OH)3 + FeSO4(Un-reacted) + Fe(OH)2 settled for its gravitation . there are two inclined sludge settler(clarifier) in the Ecotex . One being used after the
Clarifier

flocculation and onether one is used in the last stage . these two clarifier is linked with the aerobic digester where the sludge is stored

Aerobic digester is the small tank where the sludge is stored for some times foe settling .In here sludge is settled down for its own mass and then it is taken out by the sludge conditioning tank .

Filter Press
Filter Press is the pressing machine where the sludge removes its water under pressure . Figure : Clarifier Intermediate tank Intermediate tank is the where the water rest some time . .The water is then backed to the equalization tank .In here the sludge are shaped into cake form . This sludge then taken out for dumping .

SEQUENCING BATCH REACTOR (SBR)

The sequencing batch reactor (SBR) is a filland draw activated sludge system for wastewater treatment. In this system,

wastewater is added to a single or lagoon batch reactor, treated to and aeration, remove then and

undesirable discharged.

components, Equalization,

Figure : intermediate tank

Aerobic Digester

clarification can all be achieved using a single batch reactor. To optimize the performance of the system, two or more batch reactors are used in a predetermined

sequence of operations . SBR are uniquely suited for wastewater treatment applications characterized by low or intermittent flow conditions. Currently, sequencing batch reactor (SBR) technology is a well-

In Ecotex they are using Lagoon SBR system , which contain three chamber .they are currently using two chamber ,Another one is used for testing water parameter by fish cultivation . The SBR system gives them a unique miracle to treat the waste water. After treatment the water parameter comes down near to the drinking water .The working procedure of SBR is given belowInfluent wastewater generally passes

promoted and tested alternative, which has a relatively low cost and small footprint. The SBR process offers flexibility of operation, where the sequence of successive phases can be adjusted to create the required

combination of the growth conditions for different groups of microorganisms to remove different contaminants from

through screens and grit removal prior to the SBR. The wastewater then enters a partially filled reactor, containing biomass, which is acclimated to the wastewater constituents during preceding cycles. Once the reactor is full, it behaves like a conventional activated sludge system, but without a continuous influent or effluent flow. The aeration and mixing is discontinued after the biological reactions are complete, the biomass settles, and the treated supernatant is removed. Excess biomass is wasted at any time during the cycle. Frequent wasting results in holding the mass ratio of influent substrate to biomass nearly constant from cycle to cycle. Continuous flow systems hold the

wastewater, i.e.:
aerobic for COD removal only, aerobic/anoxic for COD/nitrogen removal

aerobic/

anoxic/

anaerobic

for

COD/nitrogen/phosphorus removal.

Figure: SBR layout

mass ratio of influent substrate to biomass

constant by adjusting return activated sludge flow rates continually as influent flow rates, characteristics, and settling tank underflow concentrations vary. After the SBR, the batch of wastewater may flow to an equalization basin where the wastewater flow rate to additional unit processed can be is controlled at a determined rate. In some cases the wastewater is filtered to remove additional solids and then disinfected. The solids handling system may consist of a thickener and an aerobic digester. With SBRs there is no need for return activated sludge (RAS) pumps and primary sludge (PS) pumps like those associated with conventional activated sludge systems. With the SBR, there is typically only one sludge to handle. The need for gravity thickeners prior to digestion is determined on a case by case basis depending on the characteristics of the sludge. An SBR serves as an equalization basin when the vessel is filling with wastewater, enabling the system to tolerate peak flows or peak loads in the influent and to equalize them in the batch reactor. In many conventional activated sludge systems, separate equalization is

needed to protect the biological system from peak flows, which may wash out the biomass, or peak loads, which may upset the treatment process. It should also be noted that primary clarifiers are typically not required for municipal wastewater

applications prior to an SBR. In most conventional activated sludge wastewater treatment plants, primary clarifiers are used prior to the biological system. However, primary clarifiers may be recommended by the SBR manufacturer if the total suspended solids (TSS) or biochemical oxygen demand (BOD) are greater than 400 to 500 mg/L. Historic data should be evaluated and the SBR manufacturer consulted to determine whether primary clarifiers or equalization are recommended prior to an SBR for municipal and industrial applications. Equalization may be required after the SBR, Depending on the downstream process. If equalization is not used prior to filtration, the filters need to be sized in order to receive the batch of wastewater from the SBR, resulting in a large surface area required for filtration. Sizing filters to

Accept these batch flows is usually not feasible, which is why equalization is used

Table 2: SBR Influent Characteristics

Influent Parameter Value of Ecotex BOD5 147 mg/L 98 mg/L 34 mgN/L 0 mgN/L 30,000 m3/d (7.9 MGD) Flow 49,000 m3/d (12.9 MGD)

between an SBR and downstream filtration.

TSS

Separate

equalization

following

the
TKN NO3 Total Average Influent Flow Total Average Peak

biological system is generally not required for most conventional activated sludge systems, because the flow is on a continuous and more constant basis. The SBR plant treats a wastewater stream from a

commercial textile operation. Table 3: SBR Physical Design Parameters

Design Parameter Value of Ecotex Trains Volume of Each Reactor Reactor Volume 4 5,700 m3 (1.5 MGal) Total 22,800 m3 (6.0 MGal) 5.13m 6.5m (low/high water levels)

Water Level

The original cycle settings are shown in the center of Table 4. The design objectives for Figure: SBR in Ecotex The influent characteristics for the SBR plant are shown in Table 2 and Table 3 summarizes the physical design parameters of the Ecotex Waste water treatment plant. effluent and maximum MLSS in the reactor for the SBR plant are shown in Table 5.

Table 4: Cycle Settings for the Designed and Optimal SBR Process
SBR Phases Phase length (minutes) Filling and mixing 45 filling and aeration Aeration only Mix only (anoxic) Settling Decant Desludge Total cycle length 45

Operating flexibility and control. Minimal footprint. Potential eliminating capital cost savings by

135 60 60 55 20 360

Clarifiers and other equipment. Disadvantages of SBR A higher level of sophistication is required (compared to conventional systems), especially for larger systems,

Table 5: Desired Effluent Quality and MLSS

Parameter Design Objectives (mg/L) Effluent CBOD5 15 Effluent TSS ffluent NH4 Effluent NO3 Maximum MLSS 20 3 15,10,5 3000

of timing units and controls. Higher level of maintenance (compared to conventional systems) associated with more sophisticated controls, automated switches, and automated valves. Potential of discharging floating or settled sludge during the DRAW or

Advantages of SBR Equalization, primary clarification (in most cases), biological treatment, and secondary Clarification can be achieved in a single reactor vessel.

decant

phase

with

some

SBR

configurations. Potential plugging of aeration devices during selected operating cycles

Result & Discussion Water quality monitor Ecotex have their own lab where they test their own treated water. In here some research has done. Some treated water was taken from the plant. And after testing it into the Ecotex laboratory of found the these water-

characteristics

Table 6: Water quality parameter Subject Inlet Outlet effluent effluent Flow rate 40M3/hr 40M3/hr H P 8-14 7-8 BOD 400-600 <10 PPM PPM COD 800<70 1200 PPM PPM TSS 200-500 <100 PPM PPM TDS 3000<2,500 6000 PPM PPM Oil & 30-60 <10 Grease PPM PPM Color Dark Clean Mixed Temperature 60oC <30oC

Costing Ecotex is a very cost effective textile mill. Their wastewater treatment plant is also a cost effective plant. They spend only 15 BDT/m3 to treat their water. Here is a graph of cost in month November, 2009 to treat their water

Figure: Total cost analysis in the month of November, 2009. (Provided by Ecotex) Conclusion This case study illustrates the benefits of simulation for evaluation and optimization of the operation of an SBR treating in Ecotex a high strength industrial wastewater. The waste water treatment plant in Ecotex using SBR save a lot of money. The operational Improvements indicated by the simulations were as follows: 1. High effluent TSS concentrations in the baseline operation were due to inadequate settling time in the secondary clarifiers, 2. The aeration stage in the baseline operation was far longer than necessary, consuming

Excess energy with no additional benefit, Acknowledgement 3. A reduction in the time for the aeration The author would like to acknowledge all stage could be used to provide an anoxic the stuff of Ecotex, Ecotex testing lab stage to assistant, Ecotex document database lab, Promote denitrification, and Asif Mohammad Sami (consultant and 4. The SBR treatment cycle could be designer of Ecotex), Subrata Paul (Assistant optimized to meet the stringent effluent Engineer) and all those people who help criteria for author to write this document. Average and peak flow conditions, as well as winter, spring and summer wastewater Temperatures, with the exception of the effluent NO3 at peak loading and 20C/68 F. Reference Asif Mohammad Sami, Consultant , Euroasiatic limited Subrata Paul, Engineer ,Ecotex . Dold P.L., Wentzel M.C., Billing A.E., Ekama G.A. and Marais G.v.R. (1991) Activated Version sludge 1.0 simulation programs: and Water Research Commission, P/Bag X03, Gezina 0031, South Africa. Henze M., Grady C.P.L. (Jr), Gujer W., Marais G.v.R and Matsuo T. (1987) Activated Sludge Model No.1. IAWQ

Scientific and Technical Report No.1, IAWQ, London. 33pp.

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