UNIVERSITI TEKNOLOGI MARA

FAKULTI KEJURUTERAAN KIMIA

(CPE 649 )

GROUP MEMBERS : MUHAMMAD FIRDAUS JAMALLUDDIN (2015112539)

MUHAMAD AZARUL IZHAM BIN CHE MOHD ROSLI (2015143889)

MIMI FAZZLINDA BINTI MOHSIN (2015182117)

MUHAMMAD FAIZI BIN IBRAHIM (2015135623)

AHMAD SYANIZ SYAFIQ BIN ZULKEFLI (2015116011)

MUHAMMAD NADZMI BIN ABU KASSIM (2015110065)

Remarks:
GROUP : EH2207B

DATE PERFORMED : 4 JUN 2018

PROGRAMME/CODE : EH220

SUBMIT TO : PN SUHAILA BINTI MOHD SAUID

Checked by: Recheck by:

……………………. ……………………

Date:
INTRODUCTION

Every industry that produces effluent must undergo a certain procedure

beforehand before being able to discharge their waste. Industrial Effluent
Characterization Study (IECS) is introduced for limiting the amount of effluent discharge
would require us to determine the size of each units used for the processes. The
qualitative and quantitative measurement of current capacity of a Waste Water
Treatment Plant or Sewage Treatment Plant use Industrial Effluent Characterization
Study (IECS) is their system. The IECS is important for the modelling or designing
Water Treatment Plant, and also a necessity if any sort of upgrade to the design is
required "Industrial Effluent Characteristic Study".

For this case study, the Industrial Effluent Characterization Study (IECS) for
effluent discharge from the synthetic organic chemical manufacturing plant, is going to
be determined in terms of quantity and quality of the daily waste water producing
discharge and carried out for 3
days. There are a few parameters that being included in the system such as pH,
temperature and flow rate measurement based on hourly basis.

PROBLEM STATEMENT

Maju Chemicals is a synthetic organic chemical manufacturing plant. In its

manufacturing process, many types of wastes are produced. Main sources of
wastewater generation come from process, washing and utilities. Industrial Effluent
Characterization Study (IECS) for wastewater was carried out for 3 days continuously
from 04/09/2017 to 06/09/2017 to determine the quantity and the quality of the daily
wastewater. IECS results can be referred in Table 1. The values are above the standard
value for standard B. Industrial Effluent Treatment System (IETS) is required to treat
waste stream. The waste stream condition is too dangerous to release without any
treatment.
 Table 1: Average value of IECS

PARAMETER UNIT RESULT

pH - 4.8
BOD5, 20°C mg/L 220
COD mg/L 769
Suspended Solids mg/L 462
Mercury,Hg mg/L 0.006
Cadmium, Cd mg/L 0.001
Chromium Hexavalent, Cr6+ mg/L 0.0005
Arsenic, As mg/L 0.001
Cyanide, Cn mg/L 0.12
Lead mg/L 0.04
Chromium Trivalent, Cr3+ mg/L 0.03
Copper, Cu mg/L 0.11
Zinc, Zn mg/L 3.86
Iron, Fe mg/L 0.57
Chlorine, Cl mg/L 0.01
Oil & Grease mg/L 14.2
Flowrate m3/hr 89

After a referring to ENVIRONMENTAL QUALITY (INDUTRIAL EFFLUENT)

REGULATIONS 2009, Acceptable Conditions for Discharge of Industrial Effluent or
Mixed Effluent of Standards A & B (Standard B), the data that exceed the value was pH
value, BOD5, suspended solids, cyanide, zinc and oil and grease.

ENVIRONMENTAL QUALITY (INDUTRIAL EFFLUENT) REGULATIONS 2009

Acceptable Conditions for Discharge of Industrial Effluent or Mixed Effluent of

Standards A & B
 PARAMETER UNIT STANDARD B
I Temperature °C 40
II pH Value - 5.5-9.0
III BOD at 20°C mg/L 50
IV Suspended Solids mg/L 100
V Mercury mg/L 0.05
VI Cadmium mg/L 0.02
VII Chromium, mg/L 0.05
Hexavalent
VII Chromium, Trivalent mg/L 1.0
IX Arsenic mg/L 0.10
X Cyanide mg/L 0.10
XI Lead mg/L 0.5
XII Copper mg/L 1.0
XIII Manganese mg/L 1.0
XIV Nickel mg/L 1.0
XV Tin mg/L 1.0
XVI Zinc mg/L 2.0
XVII Boron mg/L 4.0
XVIII Iron(Fe) mg/L 5.0
XIX Silver mg/L 1.0
XX Aluminium mg/L 15
XXI Selenium mg/L 0.5
XXII Barium mg/L 2.0
XXIII Fluoride mg/L 5.0
XXIV Formaldehyde mg/L 2.0
XXV Phenol mg/L 1.0
XXVI Free Chloride mg/L 2.0
XXVII Sulphide mg/L 0.50
XXVIII Oil & Grease mg/L 10
 XXIX Ammoniacal Nitrogen mg/L 20
XXX Colour ADMI 200

PROCESS FLOW DIAGRAM (PFD)

PROCESS DESCRIPTION

PRIMARY TREATMENT

ADSORBER TANK

The average value of IECS from Maju Chemicals stated that the result of
dismissed oil and grease was 14.2 mg/L. It exceeds the amount allowed in Standard B.
The oils can be removed in an absorber tank. The tank should be made by carbon.
Under calm conditions, the free oils rise rapidly to the surface. It can be removed by
using an overflow weir in the tank and a skimmer. Other than that, the tank should be
filled organoclay. It is because organoclays remove oil and grease from water at seven
times the rate of activated carbon.

GRIT REMOVAL

The second treatment that the wastewater from Maju Chemicals is going to go
through is the
grit chamber. The function of grit chamber is to remove visible or large substances that
may
present in the wastewater. There are several types of solid waste that can be present in
the
effluent stream of the synthetic organic chemical manufacturing plant. The wastewater
would most probably contain pigments, sludge, metals, ash, paints, sandpaper, paper
products, industrial by-products, metals and many more.

After grit removal, the wastewater will enter sedimentation tank. The type of
sedimentation that being chosen is type 1 which is rectangular horizontal flow type. It
used widely and sometimes baffle walls are provided to prevent short circuiting. Other
than that, maintenance is low in case of rectangular sedimentation tanks. It is also
suitable for large capacity plants. The velocity of the effluents need to be independent
so that the particles can maintain their shape and sizes during discrete settling. With
such low concentrations of suspended particles, the rate of flocculation is too small that
the values can be ignored for most calculations. The basin is divided into 4 parts:
 i. The inlet zone
ii. The settling zone
iii. The sludge zone.
iv. The outlet zone

Figure 1.2: rectangular horizontal flow type

EQUALIZATION TANK

Existing the grit chamber, the wastewater will enter the equalization tank. The
process at this section is more water added to further dilute it. Equalization tank also
acts as buffer to maintain a continuous flow to the rest of the treatment process of the
treatment process. Other than that, the function of this section to balance the flows from
the wastewater, hence the name, equalization tank. The inconsistencies that occur in
wastewater are being minimize by the equalization tank.

PH, COAGULANT AND FLOCCULANT TANK

The pH release by Maju Chemical is 4.8 and according to pH scale, the value is
in acidic range (1-6). The range allowed to be released according to Standard B,
ENVIRONMENTAL QUALITY (INDUTRIAL EFFLUENT) REGULATIONS 2009 is 5.5 to
9. Here, the chemical (base) is added to removed dissolved solid and increase the pH
value. Dissolved solid that reside in wastewater is metal, zinc, iron and many more. The
reasons of these process is to ensure the smooth flow for the next section such as
coagulant and flocculant. The next section is coagulant where alum will be added to the
wastewater. Alum is a chemical compound, which is a cation. It will cause the dissolved
solids to attract the positive ions and create a neutral charge of particles. The particle
will stick together and forming a large particle. Furthermore, a rapid mixing will be
introduced to allow the particles to be distribute evenly in the water.

The particles then stick together and have a neutral charge. In the flocculation
tank, the paddles provide slow mixing and bring the particle together and produce floc.
The reasons why the paddle moves at slow speed is because the flocs may breakdown
if rapid mixing were applied in the tank.
1ST CLARIFIER

The wastewater will enter the first clarifier after coagulation and flocculation
section. Based on the average flow of the wastewater and the efficiency, the firs clarifier
or known as settling tank will increase the detention time. At first clarifier, the suspended
solids or flocs will settle down and will gather at the bottom of the clarifier. The
suspended solids or flocs are now known as sludge. The sludge is then remove to the
sludge tank. Here it used the concept of gravity as it settle down from it position in the
wastewater towards the bottom of the clarifier.

SECONDARY TREATMENT

AERATION TANK

Oxygen utilization rate is the rate at which the oxygen is consumed by the
microorganism. It is a function of the characteristics of both the wastewater and the
reactor. Other than that, air is a fast and powerful oxidizer that it can convert unfilterable
components to a filterable type, making it easier to be removed. Aeration technique use
air diffusers to inject compressed air into the tank to stir the contents violently, mixed
mixing and distribute air through the liquid. According to Environmental Engineering
Book, use diffused air in plug-flow systems and mechanical aerators in completely
mixed systems, is a common case, although there are exceptions in both cases.

In the aeration tank, air is pump into a receiving vessel containing counter-
current flowing water, creating very small air bubbles. This ensures good air-water
contact for removing of undesirable component from the water. The method choose for
aeration technique for this plant is water-falls aerator. As the water falls, it will increase
the efficiency of aeration. Other than that, a steps or shelves is added to reduce the size
of water and the water will be spread around into thin films. With large surface area of
wastewater, it will increase the contact time and aeration efficiency. The tray slats are
place to break up the free fall of the water and create thin films before the water finally
drops into the basin. Other than that, the tray slats used to increase the contact of air
and water. The water is then further aerated before leaving through a long tube called
riser.
 The solenoid valve opens at the same time as the air pump is activated and a
mixture of air and water exit the tank via drain line. The pump and vent is being
controlled by the same source, so the vent opens as the pump is running and air is then
being exchanged. This also means that when the pump is switched off, the vent will
close and the compressed air pocket would be maintained.

2ND CLARIFIER

The second clarifier uses bioreactor type different from the first clarifier. It
requires the existence of microorganism, BOD and COD content of the wastewater. The
design of the first and second clarifier is the same.

TERTIARY TREATMENT

SAND FILTERS

The third and last step before releasing the water back to natural environment is
tertiary treatment. For this system, the chosen type is sand filters. It is because sand
filters is low operating cost. By comparing with other type of technologies in the market,
the replacement parts, consumables and repairing cost are low. Other than that, it can
be installed either above or below ground, and for this system we chose to install below
the ground to maintain the temperature. Other than that, the influent from the second
treatment section can flow by gravity or be pumped in the filter unit.

It is the final cleaning process that improves the chemical and biological
constituents in the wastewater. Example of removable constituents are bacteria, viruses
and parasites which is harmful to environment. The process started from the effluent of
secondary treatment and pumped into flash mixer. Inside flash mixer, alum is added by
using the same principle as flocculation tank, the floc with become heavy and easy to
remove in the filter and trapped by the sand. From the flash mixer, the wastewater is fed
to the sand filters by using the concept of gravity. The filters is backwashed every 24
hours to remove the floc that has accumulated in the sand. The backwash is water is
returned to primary treatment to undergo the same process.
 After that, the water flowed through the chlorine contact tank and discharge tank.
The function of chlorine contact tank is to disinfect the water and discharge tank is to
give time for the chlorine to react. Sodium bisulphite is added to remove remaining
chlorine in the water. The concentration of chlorine should low because it can affect the
aquatic life and environment when high in concentration.

Figure 1.3: Sand Filters

.
DESIGN CALCULATION

i. AVERAGE FLOWRATE CALCULATION:

- From given table 1, average flow rate for waste water to perform IECS is given 89 m3/
hr.
- In order to perform IECS, safety factor value is estimated to be 10%

Thus,

Average mass flow rate = mass flow rate (m3/ hr.) x safety factor (%)
m3 m3
= ( 89 x 10 %) + 89
ℎ𝑟 ℎ𝑟

m3
= 97.9
ℎ𝑟

- From equation :

Design flow rate = (2.5 x WW flow rate)

m3
= 2.5 x 97.9 ℎ𝑟
m3 hr
= 244.75 ℎ𝑟
x 24 𝑑𝑎𝑦
m3
= 5874 𝑑𝑎𝑦
ii. GRIT REMOVAL

Assumption:
- Assuming settling velocity at 0.02 m/s.
- Settling velocity has been found at range of 0.15 – 0.45. Thus flow through velocity will
be maintained by proportioning weir at 0.3 m / s. (Table 5.4-Design parameter of
aerated grit chamber)
- Rectangular section with depth 1.5 x width at maximum flow.

Thus,

Ax = w x 1.5w (equation 1)

Where,

𝑄
Ax = (equation 2)
𝑉ℎ
m3 s d 𝑚𝑖𝑛
Ax = 5874 x x x
𝑑𝑎𝑦 0.3 𝑚 1440 𝑚𝑖𝑛 60

= 0.2266 m2

Substitute equation 1 into 2 and rearrange.

 w = 0.3887 m

D = 0.3887 m X 1.5

= 0.5831 m

Settling velocity = 0.02 m/s

td = D / vt

= 0.5831 m / (0.02 m/s)

= 29.155 s

In determination length of grit removal:

L = td vh

= (29.155 s) x (0.3 m/s)

= 8.7465 m

Thus, overall dimension of grit chamber tank obtained:

w = 0.3887 m

D = 0.5831 m

L = 8.7465 m

iii. COAGULANT TANK

In performing coagulant design, detention time was assuming to be 5 min:

Thus volume of coagulant tank:

𝑚3 1 𝑑𝑎𝑦 1 ℎ𝑟
Volume = 5874 x x x 5 min
𝑑𝑎𝑦 24 ℎ𝑟 60 𝑚𝑖𝑛

= 20.3958 m3
iv. FLOCCULENT TANK

In performing coagulant design, detention time was assuming to be 40 min:

Thus volume of coagulant tank:

𝑚3 1 𝑑𝑎𝑦 1 ℎ𝑟
Volume = 5874 x x x 40 min
𝑑𝑎𝑦 24 ℎ𝑟 60 𝑚𝑖𝑛
= 163.1667 m3

v. 1ST CLARIFIER

𝑚3
Volume = 5874
𝑑𝑎𝑦

- in order to achieve highest efficiency of suspended solid removal, overflow rate was
𝑚3
assume to be 18 (figure 5-13 suspended solid as a function of flow rate)
𝑚2 .𝑑𝑎𝑦
- Required surface area for 1st clarifier is:

𝑚3 𝑚3
5874 / 18 = 326.33 m2
𝑑𝑎𝑦 𝑚2 .𝑑𝑎𝑦

- Then, diameter of the 1st clarifier tank:

4𝐴
D = ( )1/2
𝜋
4 𝑥 326.33
=( )1/2
𝜋

= 20.38 m

Assuming depth of sidewall is 5m, volume of tank:

326.33m2 x 5 m = 1631.65 m3

Detention time at average flow rate is

𝑚3
1631.65 m3 / 5874 = 0.27 day
𝑑𝑎𝑦

24 ℎ𝑟 60 𝑚𝑖𝑛
0.27 day X x = 388.8 min
1 𝑑𝑎𝑦 1 ℎ𝑟
 vi. AERATION TANK

Assumption:

i) Øc = 10 d
ii) MLLS concentration 6000 mg /L = 6 kg/ m3 (table 5-6)
iii) Initial BOD5 = 220 mg/L , final desire standard B BOD5 = 50mg/L
iv) Kd = 0.05 d-1
v) Y = o.5 kg biomass / Kg BOD utilized

From eqn (5-15)

1 𝑄𝑌(𝑆𝑜−𝑆)
= – kd
𝑄𝑐 𝑉𝑋

𝑚3 𝑘𝑔
1 5874𝑑𝑎𝑦(0.5)(0.22−0.05)𝑚3
= 𝑘𝑔 – 0.05
10 𝑉(6𝑚3)

Rearrange:

V = 554.7667 m3

At equilibrium:

𝑚𝑎𝑠𝑠 𝑜𝑓 𝑠𝑜𝑙𝑖𝑠 𝑖𝑛 𝑟𝑒𝑎𝑐𝑡𝑜𝑟 𝑉𝑋

Qc = =
𝑚𝑎𝑠𝑠 𝑜𝑓 𝑠𝑜𝑙𝑖𝑑 𝑤𝑎𝑠𝑡𝑒𝑑 𝑄𝑤𝑋𝑢

𝑉𝑋
QwXu =
𝑄𝑐

𝑘𝑔
554.7667 𝑚3 𝑥 6𝑚3
=
10 𝑑

= 332.86 kg/d
 vii. ANAEROBIC TANK

Wastewater Treatment plant Sludge

Influent SS = 462
Influent BOD = 220 mg/L
Effluent BOD = 50 mg/L
Flow = 5874
Primary clarifier diameter = Primary = 5.0% solids
11.76 m Secondary = 0.75 % solids
Aerator volume = 554.7667 Thickened = 4.0 % solids
m3
MLLS in aerator = 6kg/m3

- Area of primary clarifier calculated = 108.7778 m2

- From figure 5-13, the efficiency first clarifier is
SS = 73.5 %
BOD = 37.5 %
- The mass of primary solid removed
Mp = β x SS x Q
= 0.735 x 0.462 kg/m3 x 5874 m3/d
= 1994.6342 kg/d
- The volume of primary sludge given by eqn 5.35

Vp = Mp / (1000. S)

= 1994.6342 kg/d / (1000 kg/m3. 0.05)

= 39.89 m3/d

viii. 2ND CLARIFIER

Food consume in the reactor:

i) BOD in = (1- 0.375) 220mg/L = 137.5mg/L

ii) BOD out = effluent BOD = 50 mg/L
iii) BOD consumed in the aerator = 137.5mg/L - 30 mg/L
= 87.5 mg/L

0.0875 kg/ m3 x 5874 m3/d = 513.975 kg/d

- Biomass in reactor

6kg/m3 x 554.7667 m3 = 3328.6002

- Food biomass ration:

𝑘𝑔
513.975
𝑑
= 0.15 d-1
3328.6002 𝑘𝑔

- From figure 5.37, biomass conversion factor is 0.22

- Mass of secondary solid
Ms = Y’ x BOD5 x Q
 = 0.28 x 0.0875 x 5874 m3/d
= 143.913 kg/d

- Volume of secondary sludge:

𝑀𝑠
Vs =
1000 𝑥 𝑆

143.913 𝑘𝑔/𝑑
=
1000 𝑥 0.0075

= 19.18 m3/d

- Thus, total mass of sludge

Mt = Mp + Ms
= 1994.6342 kg/d + 143.913 kg/d
= 2138.5472 kg/d
- Thus, total volume of sludge

Vt = Vp + Vs

= 39.89 m3/d + 19.18 m3/d

= 59.07 m3/d

ix. RAPID SAND FILTER

Assumption:

a) Backwash = 1%
b) .Interruption time 1hr
c) Filtration rate = 8000 l/hr.m2
d) Flowrate = 5874 m3/d

1𝑑 24 ℎ
Total influent = (5874 x 1.01 m3/d) x x
24 ℎ 23 ℎ

= 257.9452 m3 /hr

1ℎ𝑟.𝑚3 1000𝑑
Area = 257.9452 m3 /hr x x
8000𝑑 1 𝑚3

= 32.24m2
Solid waste
Parameter Result
IETS Sludge 100 MT/yr
Used Oil 2 m3/yr
Discarded containers/barrels 2000 Nos/yr
Spent solvent 3680 m3/yr
Spent catalyst 64 MT/yr
Trash 10 MT/yr
Kitchen Waste 10 MT/yr

Most of the solid wastes that were produced from Maju Chemicals were considered as industrial
waste because Maju Chemicals is a chemical manufacturing plant. However, there are wastes
produced from Maju Chemical manufacturing plant that can also be considered as municipal
solid waste such as kitchen waste and trash.

KITCHEN WASTE
Kitchen waste that produced by the manufacturing plant is considered as municipal solid waste
because the main source of the waste is coming from the canteen in the manufacturing plant.
The canteen usually disposed their leftover food or waste from their food preparation. All of this
waste that were produced from canteen mainly an organic waste and they are biodegradable.

Instead of dispose the kitchen waste to the landfill, the kitchen waste can be used as raw
material to produce compost (soil conditioner) and methane gas. In order to produce compost or
methane gas, the kitchen waste need to undergo recovery process of biological conversion
products. In this process, the organic waste will decompose with the help of bacteria and
microorganism into compost and methane gas. The processes involved are aerobic conversion
and anaerobic conversion.

1. Aerobic conversion (composting)

Aerobic conversion is similar to natural decomposition. In this process, the bacteria

decompose the organic waste with presence of oxygen. The end product of an aerobic
 process from the bacteria and microorganism are mainly carbon dioxide and water. The
compost produced will consist of nitrate, phosphate and sulphate that are decomposed from
the organic waste. The compost produced is a crucial nutrient for plants growth.

2. Anaerobic conversion

In an anaerobic process, there is an absence of oxygen in the system. The bacteria will
decompose the organic waste without supply of oxygen and produce methane gas as final
product. The methane gas produced can be use a fuel for energy generation for utilities in
the manufacturing plant or can be sell to industry requiring methane gas.

TRASH
Trash from Maju Chemical’s company is mainly produced from office and kitchen area. Office
area commonly disposed paper, cardboard, paper clip and stationery waste. However, it is
estimated that paper make up the highest percentage of the waste disposed from office area.
While for trash produced from kitchen area, it is mainly consist of food packaging and food
waste.

It is preferable to recycling the recyclable material from the trash while organic waste in trash
from kitchen area can be process under either aerobic or anaerobic conversion.

1. Recycling

Recycling means to collect and separate solid waste for the purpose of producing products.
Recycling can avoid the waste of potentially useful materials and reduce the consumption of
fresh raw materials. Recyclable materials include glass, paper, metal, and plastic. The
separation of recyclable materials from the trash can reduce the amount that will be
disposed to landfill or incineration.

2. Sanitary Landfill

Sanitary landfill is a physical facilities used for the disposal of residual solid wastes in the
surface soils of the earth intended to be permanent. This method involves burying the solid
waste. The facility is isolated from the environment until the buried waste is completely
degraded biologically, chemically and physically.
DISCARDED CONTAINER/BARRELS
Unwanted container or barrels are disposed from the manufacturing plant after the
container/barrels damaged or became unreliable or there is no requirement for the
container/barrels. The container might be used as a raw material or product storage hence the
container/barrels might have a trace of hazardous materials. It is preferable to dispose the
discarded container/barrels to the sanitary landfill by using waste management contractor.

CONTRACTOR

1. Alam Flora Sdn Bhd

Among service provided by Alam Flora Sdn Bhd that can be consider for solid waste
disposal for Maju Chemical is:

 Collection of various recyclables materials

 Food waste composting
 Cover areas in Federal Territory of Kuala Lumpur and Putrajaya, and Pahang

2. SWM Environment Sdn Bhd

Service provided and facilities equipped in SWM Environment:

 Sanitary landfill equipped with leachate treatment, landfill gas extraction, and waste-
to-energy facilities.
 Collection of various recyclable items.
SCHEDULED WASTES

Based on the wastes that were produced from Maju Chemicals, there are several
industrial that be categorized as scheduled wastes. According to EQA (1974), scheduled waste
is define several wastes in the regulation that be prescribed by the minister. The wastes are
IETS sludge, used oil, spent solvent and spent catalyst where are considered as scheduled
wastes.

IETS SLUDGE
Industrial Effluent Treatment System (IETS) sludge is the waste or any deposit in the
formed of liquid, deposit caused by physical, biological, chemical other that be treated or
discharged by the industrial. The characteristics of the IETS sludge that produced by the Maju
Chemicals is toxic. The warning label for IETS sludge:

Figure 1Toxic waning label

The list of the SW codes for the IETS sludge are SW204 because sludge containing
lead, cadmium, chromium hexavalent, zinc, copper and iron and SW412 is sludge containing
cyanide.

The container that suitable used to store IETS sludge is open top drum with cover and
clamp (steel). The container used to stored IETS sludge and the container are without hole and
bulge to prevent to react with air and free from dent and corrosion. Figure below showed the
open top drum with cover and clamp (steel).
 Figure 2 Open top drum with cover and clamp (steel)

SPENT SOLVENT
Spent solvent is the solvent that be used and resulted contaminant where can no longer
function the purpose. Spent solvent is also formed without processing. The characteristic of
spent solvent as SW wastes is flammable or ignitable because in the based on the scheduled
wastes of potential incompatibility, if spent solvent is in group 1-B if mixed with substances in
group 1-A for example alkaline cleaner or caustic wastewater it will cause heat generation and
violent reaction. Besides, the other characteristic of spent solvent is toxic. Based on the
scheduled wastes of potential incompatibility, the spent solvent can be considered in group 2-B
where if mixed with group 2-A such as sodium or lithium it will result release of toxic substance
that can cause fire and explosion. The other characteristics are corrosive because inorganic
solvents can be in form acid or alkali which are highly corrosive if the substances is
concentrated. The warning label for spent solvent:

Figure 3 Figure 4 Figure 5

Figure 3 is flammable hazard label, figure 4 is toxic hazard label and figure 5 is corrosive hazard
symbol.

The SW codes for the spent solvent are SW 206 is spent inorganic acid, SW301 is spent
organic acids with pH less or equal to 2 which are corrosive or hazardous, SW 402 spent alkalis
with pH more or equal to 11.5 which are corrosive or hazardous SW 322 is waste of non-
halogenated organic solvents and SW 323 is halogenated organic solvents. The SW 206,
SW301 and SW 402 for spent inorganic solvents and SW 322 and SW 323 for spent organic
solvents.

The container is suitable is bunghole drum (plastic). This container is use to store the
solvents and corrosive acids or alkalis. This container do not have hole and bulge and free dent
and corrosion. The figure below is bunghole drum (plastic).

Figure 6 Bunghole drum (plastic)

SPENT CATALYST
Spent catalyst is the catalyst that be used in industry and no longer have a purpose to
used it. The spent catalyst can be metal. The metal characteristic is reactive. However, in the
scheduled wastes of potential incompatibility the spent catalyst is categorized in group 3-A and
if the spent catalyst react with substances in group 3-B will caused fire and explosion and
generated of flammable of hydrogen gas. Hence, the scheduled waste characteristic of spent
catalyst can be ignitable. The warning label for spent catalyst:
 Figure 8 Flammable hazard label Figure 7 Reactive hazard label
The SW code for catalyst is SW 202 is waste catalyst. The container use for spent
catalyst storage is open top drum with cover and clamp (plastic). The container is used to store
solid waste like spent catalyst and the container is without hole and bulge and free dent and
corrosion. The figure below is open top drum with cover and clamp (plastic).

Figure 9 Open top drum with cover and clamp (plastic)

USED OIL
Used oil is the any oil that be no longer be used from industrial that be produces by Maju
Chemicals. The waste of characteristic of used oil is ignitable. The used oil is flammable waste
and categorized in group 2-B in scheduled wastes of potential incompatibility and mix with
substances in group 2-A such as asbestos or pesticides can cause toxic substance release and
fire or explosion. Thus, the used oil can be characterized as toxic. The hazard label for used oil:

Figure 11 Toxic hazard label Figure 10 Flammable hazard label

The SW codes for used oil are SW 305 is spent lubricating oil, SW 306 is spent hydraulic
oil, and SW 314 is oil or sludge from oil refinery plant maintenance operation.

The storage for used oil is intermediate bulk container. This container used to broad
range of waste streams like oils. The storage do not have hole and crack. The figure below is
intermediate bulk container.

Figure 12 Intermediate bulk container

The table below showed list of the SW code based on the wastes produced by Maju Chemical,
suitable container to store the waste and warning label that be used for the scheduled wastes.

Scheduled Hazard label SW code Storage use

waste
IETS sludge SW 204 Open top drum with cover and
SW 412 clamp (steel)
Spent solvent SW 206 Bunghole drum (plastic)
SW 301
SW 322
SW 323
SW 402
Spent catalyst SW 202 Open top drum with cover and
clamp (plastic)

Used oil SW 305 Intermediate bulk container

SW 306
SW 314
AIR POLLUTANTS GENERATION

Air pollution is one type of pollution usually occurred by human activity including from the
emission of industry, open burning, emission of transportation, and etc. Despite of emission of
all these kind contaminants to surrounding, this emission could control can be controlled
whether by reduce its concentration to allowable limit or totally eliminated the contaminant
before emit by treatment process. There are some approaches to contaminant control of
particulate and gaseous contaminant. The approaches for air pollution control are;

DILUTION

Dilution is one of the reducing type of control pollution by lowering its concentration before emits
to surrounding; the ways they usually dilute the gaseous contaminant is via uses of tall stack. By
this way, tall stack are being said may penetrate the inversion layer and disperse the
contaminants so that ground level contaminants are reduced. This ways also has its drawback
because it is known as dilution devices that are spreading air contaminants around the globe to
levels at which their harmful effects are less noticeable near their sources (Peavy, 1985).
However, dilution approaches is seen as the best and short term control measure and still can
be improve its capabilities in controlling air pollution.

CONTROL AT SOURCE

Control of contamination at source is more considerable and effective method than dilution. This
is because this method is suit for long term used in control of air pollution by industry which
operates for long term period as well. Control of pollutant at source can be accomplished by
several different means including proper use of existing equipment by proper operation and
maintenance are said can be greatly reduced the contaminant emission. According to (Peavy,
1985) hydrocarbon and carbon monoxide emission can be reduced from 20 to 50 percent its
concentration through proper and regular as well as competent inspection and maintenance of
equipment. Next is by changing the process being used by identifying which process emits and
contribute most contaminant and how to solve by some treatment process change or
installation. Last but not least, the most and widely applied in industry in controlling emission of
air pollution at their sources is to install control devices designed according the type of
contaminants appeared. This control a device is most effective in controls both emissions like
particulate and gaseous contaminants.
 TABLE 1 Air Pollutant Contaminant Emmision Limit Value

Reference: Environmental Quality (Clean Air) Regulation 2014

According to the table 2, the air pollution contaminants emissions from the flue and stack
process are tabulated. Based on the table, at the flue gas stack, the contaminant obtained are
particulate matter, sulphur dioxide and nitrogen dioxide. Two out of three contaminants at the
flue gas stack need to be treated as the limit value for contaminant concentration exceed the
requirement from the Environmental Quality (Clean Air) Regulation 2014 which is for particulate
matter is 50 mg/m3 and sulphur dioxide is 100 mg/m3. However, for nitrogen dioxide can be
emits directly as their concentration are far and below the limit value as gazetted. While for
process stack 1, the gaseous of nitrogen dioxide are very little its volume as it is can be ignored
as well. But the ammonia that flow in the process stack 1 must be reduces before release to the
surrounding. And last emission for air pollution control is at the process stack 2 which the
component found are hydrochloric acids and chlorine gas and both of them above the limit
value.

CYCLONE SEPARATOR

Cyclone separator function has similarity like extractor that are continuous feed of dirty air. Dirty
flue gas is fed into a chamber and the chamber creates a spiral vortex. Gas which light
components contain less inertia causes it much easy for them to influence by the vortex and
move through it. Basically, larger components of particulate matter contain more inertia and are
not as easily influenced by the vortex. Cyclone component which has chamber as a function to
promote the collection of particles through the bottom of the container and the cleaned flue gas
exit to top of the chamber. Cyclone separators have an ability to remove up to 50-99% of all
particulate matter in flue gas based on particle size. Cyclone separators are beneficial as it
easily be maintain, well cost and need little space to build. Moreover, the removed particulate
matter is collected when dry, which makes it easier to dispose.

Figure 1 Cyclone Separator Unit

Particulate Matter Control Equipment at Flue Gas Stack

Flow rate of gas inlet = 12 m3/s Temperature inlet = 149oC

Assumptions made:

Percent removal efficiency is 95% targeted

Particle size = 10 µm

Inlet gas velocity = 30.77 m/s

Density of particle = 1500 kg/m3

In order to achieved the 95% removal efficiency, from the figure 9.3b, the relative size,

d/d50 = 3.279

10/ d50 = 3.279

d50 = 3.05 µm

= 3.051 x 10-6 m

d50 = 9µb/2лNeviρp

*where Ne in number of turn = 5 turns and at the temperature 149oC, the gas viscosity,

µ = 2.4 x 10-5 kg/m.s

b = d502лNeviρp / 9µ

= 0.0625 m

b = D/4

D=bx4 h = D/2

= 0.25 m = 0.125 m

*thus, area of all inlets = 12 m3/s / 30.77 m/s

= 0.39 m2

And area of inlets = 0.39 m2 / 50 tube of cyclone

= 7.8 x 10-3 m2
 Picture 1 the Schematic Diagram of Cyclone

Separator Unit for Particulate Removal

SPRAY TOWER

In a spray tower, particulate-laden air passes into a chamber where it contacts a liquid spray
produced by spray nozzles. Towers can be placed in either vertical or horizontal waste gas
flow paths. The liquid spray can be directed counter to the gas flow, in the same direction as
the gas flow, or perpendicular to the gas flow.
 Figure 2 Spray Tower/ Scrubber Unit Operation

The gas flow enters at the bottom of the tower and flows upward. Water sprays downward
from nozzles mounted on the walls of the tower or mounted on an array at the tower center.
Water droplets capture particles suspended in the gas flow through impaction, interception
and diffusion. Droplets large enough to settle by gravity collect at the bottom of the chamber.
Droplets that remain entrained in the gas stream are collected on a mist eliminator upstream
of the nozzles.

SO2 Control Equipment at Flue Gas Stack

Gas flow rate inlet = 12m2/s

Assumptions

Gas velocity inlet fro vertical tower = 2.3 m/s

D = √ (qv x 4) / (ug x л)

= √ (12 x 4) / (2.3 x л)

= 1.8225 m

Picture 2 The Schematic Diagram Of

Spray Tower At The Flue Gas Stack

NH3 contaminants at process stack 1

Gas flow rate inlet = 8m2/s

Assumptions

Gas velocity inlet fro vertical tower = 2.3 m/s

D = √ (qv x 4) / (ug x л)

= √ (8 x 4) / (2.3 x л)

= 2.1044 m

Picture 3 The Schematic Diagram Of

Spray Tower At The Process Stack 1

CONDENSER

Condensation is a process used heavily throughout industry to convert a gas or vapor to

liquid. Any gas can be reduced to a liquid by sufficiently lowering the temperature (or
increasing the pressure). Condensation can be used to remove a pollutant from a gas
stream if the dew point of the pollutant is higher than the carrier gas (or non-pollutant gas). If
this is true, the total gas stream can be reduced in temperature to below the pollutant’s dew
point, which will then separate the pollutant from the remaining gas stream as a liquid. The
most common form of condensing is by lowering temperature. While increasing pressure can
be equally effective, a pressure condensing technique is usually more expensive.
Condensers are simple and relatively inexpensive devices that normally use water or air as
the coolant. In modern applications for air pollution control, condensers are commonly used
as pre-treatment devices. Condensers work when the warmer vapor stream contacts a
cooling medium. The heat from the warm gases is transferred to the cooler medium. Then,
as the warm gas stream begins to cool, the kinetic energy of the gas is reduced. Condensers
used for pollution control are contact condensers and surface condensers. Direct contact
condensers operate by mixing the contaminated gas stream with the cooling medium.
Indirect or surface condensers work when the contaminated gas stream is kept separate
from the coolant medium, similar to a radiator or heat exchanger. Removal efficiencies of
condensers typically range from 50 percent to more than 95 percent, depending on design
and applications.
 Figure 3 Contact condenser

Figure 4 Surface condenser

HCl and Cl2 Control Devices at Process Stack 2

Gas flow rate inlet = 5 m3/s

Temperature hot gas inlet = 90oC

Assumptions

Temperature hot gas outlet = 50oC Thin = Thout =

90oC 50oC
Temperature cold fluid inlet = 25oC
∆T1 ∆T2
o
Temperature cold fluid outlet = 40 C
Tcout = Tcin =
2
Overall heat transfer coefficient = 350 W/m .K 40oC 25oC

Power of condenser = 36 W
Log mean temperature, ∆Tlm = (∆T1 - ∆T2) / ln (∆T1/ ∆T2)

= (50 - 25) / ln (50/ 25)

= 36.06oC

Q = UA ∆Tlm

A = Q / U∆Tlm

= 35W/ 350 W/m2.K (36.06oC 273 K)

= 3.235 X 10-4 m2

A = Лd2/4

d = (Ax4/л)1/2

= 0.0203 m

Picture 4 The Surface Condenser Schematics Design

REFERENCE

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wastewater-organoclays

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httpsr://www.suezwatertechnologies.com/handbook/ext_treatment/ch_4_aerati
on.jsp

Retrieved 28th May 2018, https://www.wplinternational.com/product/wpl-sand-

filter-polishing-plant/
Retrieved 28th May 2018,
https://www.sydneywater.com.au/Education/Tours/virtualtour/html/tertiary-
treatment.html

Carlson J. (2016), Air Pollution Control Technology Review: Condensation, retrieved on 29

May 2018 from https://www.cpilink.com/blog/air-pollution-control-technology-review-
condensation.

Murty, B. P., 2004. Environmental Meteorology, I.K. International Pvt. Ltd., New Delhi.

Nevers, N.D. 2000. Air Pollution Control Engineering, Second Edition, Pub., McGraw Hill,
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Rao, M.N. and Rao, H. V. N., 1993. Air Pollution, Tata Mc-Graw Hill, New Delhi.