Beruflich Dokumente
Kultur Dokumente
WASTE TREATMENT
10.0 INTRODUCTION
Waste treatment is one of the important considerations that must take into concern in
plant operation which mostly these wastes are synthesized from the processes.
Handling procedures and methods of these wastes need to be specified in order to
meet the standard of Department of Environment (DOE). Industries are required to
comply with both air emission and effluent discharge standards which are regarded
as acceptable conditions allowed in Malaysia, as stipulated in the Environmental
Quality (Clean Air) Regulations 1978 and the Environmental Quality (Sewage and
Industrial Effluents) Regulations 1979.
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The law requires that these wastes be properly packed, labeled, stored, and
inventoried. Scheduled wastes are also required to be treated and disposed of at
facilities approved by the authorities.
The waste management complied with the standard rules and regulations of
sewage and effluent, scheduled waste, green air and environmental impact
assessment (EIA) 1989. Although the waste management in this plant complied with
the rules and regulations, it is more likely as end-pipe of treatment, cleaner
production technology which is waste minimization.
Liquid waste that generated from this plant is the waste water. The main source of
the waste water comes from cooling tower blowdown. The quantity of cooling tower
blowdown is reduced, thereby reducing treatment requirements. Higher circulating
water control limits is considered where the warm water from the heat exchanger is
circulate to heater. Cooling water is treated as make up water or a side stream from
the system. Generally, the waste water through cooling water system effluent could
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be discharged directly if chlorine residuals are acceptable. The waste water released
into the sea is following standard B.
Gaseous waste from the flare system is released to the atmosphere which
contents a number of small amounts of carbon dioxide, carbon monoxide, nitrogen,
Oxygen and water vapor. Since flare system use to burn harmful gaseous, the
gaseous that released to the atmosphere must comply with the standard of EQA
1974, Environmental Quality (Clean Air) Regulations 1978. Furthermore, basically
the amount of carbon monoxide released from the Tetradecene plant is considered
under controlled though it is one source of the air pollution.
Solid waste in tetredecene plant comes from reactor and waste water treatment
facility. Catalysts that have been used for an estimated time is treated as solid waste
and will be sent for regeneration. Besides that, solid waste also arises from the
industrial activities and typically includes rubbish, ashes and demolition construction
waste. Sludge obtained from the wastewater treatment also needs to be considered
and must follow the standard of Environment Quality Act 1974 and will be sent to an
authorized company which is Kualiti Alam.
Industrial wastewater treatment covers the mechanisms and processes used to treat
waters that have been contaminated in some way by man's industrial or commercial
activities prior to its release into the environment or its re-use.
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Most industries produce some wet waste although recent trends in the
developed world have been to minimize such production or recycle such waste within
the production process. However, many industries remain dependent on processes
that produce water based waste stream.
i) Preliminary Treatment
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These floes can be subsequently removed in clarifier and the residues in
filters. The flocculation basin often has a number of compartments with decreasing
mixing speeds as the water advances through the basin. This compartmentalized
chamber allows increasingly larger floes to form without being broken apart by the
mixing blades. Figure 10.1 below shows the process of coagulation and flocculation
in the wastewater treatment.
In this primary treatment, the raw waste water will pass through the Corrugated Plate
Interceptor, CPI Separator. This separator is mainly use for separation of heavy oil
contaminated water from effluent water or suspended solids for oily water treatment
in an oily water system. The basic principle in separation the two phases in oily water
system by Gravity Separation. The phase with high density will settle and with lower
density float to the surface of fluid. In some cases chemical coagulation and
flocculation is needed for removal of the impurity by making them heavier or lighter.
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After skimming oil, treated water in CPI Separator is transferred to biological
pond in the plant by CPI Separator Sump Pump. Skimmed oil in CPI Separator is
drawn off to a drum sent to the biological pond via CPI Separator Slump Pump.
1. Activated sludge:
It consists in a set of two basins which are for aerobic and anaerobic. For aerobic air
is pumped through perforated pipes at the bottom of the basin, air rises through the
water in the form of many small bubbles. It is form of pretreatment such as oil
removal, which favor intimate contact between wastewater with microbes and
oxygen in a reactor to optimize the growth and efficiency of the biomass. The
microorganisms act to catalyze the oxidation of biodegradable organics and other
contaminants such as ammonia and will generate harmless by products such as
carbon dioxide, water, and excess biomass (sludge).
The second basin is a settling tank, where water flow is made to be very quiet
so that the cellular material may be removed by gravitational settling. Some of the
cell material collected at the bottom is captured and fed back into the first basin to
seed the process. The rest is treated anaerobically which are without oxygen until it
is transformed into a compost-type material such soil.
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The cost of an activated-sludge system is chiefly due to the energy required
to pump air at high pressure at the bottom of the aerator tank (to overcome the
hydrostatic pressure of the water). Another disadvantage is that the operation is
accomplished in two separate basins, thereby occupying a substantial amount of real
estate.
2. Trickling filter:
A trickling filter consists in a bed of fist-size rocks over which the wastewater is
gently sprayed by a rotating arm. Fungi and algae develop on the surface, growing
by intercepting organic material from the water as it trickles down. Since the water
layer passing over the rocks makes thin sheets, there is good contact with air and
cells are effectively oxygenated. Water needs to be trickled several times over the
rocks before it is sufficiently cleaned.
Figure 10.2: Cross section of trickling filter (Source: Hammer and Hammer,1996)
This is essentially a variation on the trickling filter, with the difference being that solid
material on which slime grows is brought to the water rather than water being
brought to it. Rotating disks alternate exposure between air and water.
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Figure10.3: Rotating biological contactor cross section and treatment system: a)
RBC cross section; b) RBC included in secondary wastewater treatment system.
(Source: Hammer and Hammer, 1996)
After mechanical cleaning, specific bacteria are use in order to purify the wastewater
which are aerobic and anaerobic processes. The consequences that arise from two
types of processes are such below:
Anaerobic Aerobic
Operating cost Low High
The inflow of the wastewater is diluted in this plant and therefore they are
aerobic process. The objective of the biological cleaning is to convert energy rich
material with the high molecular weight into material with the less energy and having
the molecules that are small. The ends products are water and carbon dioxide. After
that the water will go to the tertiary treatment before discharge. The sludge in this
process will be dispose and send to authorize company. It also enters the
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wastewater as return sludge from secondary clarifier. Returning the sludge like this
way will make sure that bacteria survive for a long enough time.
The clarifier header is use for the gentle suction action to achieve the highest
sludge withdrawal concentration of any biological clarifier sludge device, and greatly
reducing sludge pumping costs. Its hydraulic design permits rapid and uniform
sludge withdrawal throughout the entire area of the clarifier over a 6 to 1 flow range,
and it has flat clarifier floors, which reduces excavation costs.
v) Tertiary Treatment
Tertiary treatment required to meet strict effluent limits of discharge from Department
of Environment, DOE under Environmental Quality Act 1974 or to allow for recycle
and reuse of the treated effluent for cooling tower make-up, boiler feedwater, or other
processes. The removals of suspended solids, oil and grease, or COD are extremely
low concentrations.
Figure 10.4: Granular media filter cycle (Source: Jackson & Letterman, 1998)
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10.2.2 Mass Balance Calculation of Wastewater Treatment
The wastewater from the plant cannot be channeled into the sewage system without
being treated. Before it really safe to release to the sewage system, the calculations
is needed to make sure it really be treating. The mass balances are needed to make
sure the treatments are operating accurately.
Oily mixture
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10.2.2.2 Mass Balance at Biological Treatment
W2 Biological W3
treatment
CO2
Water
Sludge
W2 = 645.014 kmol/hr
= 612.763 kmol/hr
Since W2 = W3 + Sludge
= 32.251 kmol/hr
W3 Filtration W4
Treated
Effluent
Sludge
W3 = 612.763 kmol/hr
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10.2.3 Energy Balance
General equation:
kmol kJ
Hinlet = 13888.9 75.4 (60 o C )
hr o
kmol C
= 6.283 x 107 kJ/hr
Houtlet = Hr + Hw Eqn 10.5
For Hr:
m3 kg kmol
m = 208.333 x 1000 3 x
hr m 18kg
= 11574.056 kmol/hr
kmol kJ
Hr = 11574.056 75.4 (30.00 o C )
hr o
kmol C
= 2.618 x 107 kJ/hr
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For Hw:
m3 kg kmol
m = 2.25 x 1000 3 x
hr m 18kg
= 125kmol/hr
kmol kJ
Hw = 125 75.4 (30.00 o C )
hr o
kmol C
= 2.827 x 105 kJ/hr
Q = ΔH Eqn 10.6
= Hinlet – Honlet
= (6.283 x 107 – 2.618 x 107 - 2.827 x 105) kJ/hr
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10.2.4 Wastewater Treatment Plant Process Layout
Process unit
wastewater
Preliminary
treatment
Treated
Raw effluent
Influent Primary Secondary Biologicl Biological Tertiary
oil/water Oil/water treatment clarification Treatment
separaton separation
Solid To disposal/
Solid
handling oil recovery To disposal
handling
Oil To disposal/
recovery oil recovery
In every plant, wastewater treatment is very important. Without all the utilities, plant
cannot be proceeding further for the process. The waste treatment layout show how
effective the process operating to treat the waste produce from process. Table below
shows the equipment use for wastewater process.
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Table 10.2: Major Equipment Use in Wastewater Treatment
Unit Operation
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10.2.6 Mechanical Design of Wastewater Treatment
Assumed values:
XU = 6500 mg / L
Influent BOD, SO = 180 mg / L
Effluent BOD, S = 10 mg / L
kg biomass
Cell Yield coefficient, Y 0.5 kg/kg
kg BOD utilized
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Mixed Liquor Suspended Solid (MLSS), X = 3000 mg / L
1 QY S O S
kd Eqn 10.7
C VX
1
6000 m d 0.50.18 kg m 0.01kg
3 3
m3 0.05d 1
10d V 3.00 kg m 3
170 m 3 d
0.10d 1 0.05d 1
V
170 m 3 d
0.15d 1
V
V 1133.333 m 3
Usually the hydraulic retention time, θ range from 3 to 5 hours,(Peavy, Rowe, and
Tchobanoglous,1985)
Check for θ:
V
Eqn 10.8
Q
θ = 1133.333 / 6000
= 0.189 d
= 4.533 hr
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At equilibrium condition;
QR recycleflow rate
Eqn 10.10
Q w aste w ater flow rate
Assumption:
Effluent biomass concentration is negligible compared to the effluent and underflow.
QO X QR X QR X U QW X U
QR X X U QW X U QO X
QW X U QO X
QR Eqn 10.12
X XU
339.999 kg d 6000 m 3 d 3.00 kg m 3
3.00 kg m 3 6.50 kg m 3
5045.715 m 3 d
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QR 5045.714 m 3 d
Q 6000 m 3 d
0.841
Q = 6000 m3/d
MLSS = 3 kg/m3
Take solid loading rates at 3.0 kg/m2hr (typical design value) as suggested by
Reynolds and Richards (1982).
= 16.352 m
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Use sidewall depth of 3 m (typical design value), Shundar Lin, 1985
6000 m 3 / d
HLR =
210 m 2
= 28.571 m / d
= 116.797 m2/d
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10.2.7 Equipment costing
The estimation of equipment cost for example for CPI Separator is based on bare
module cost at base conditions, which is at operating pressure (near-ambient
pressure). Therefore:
= 13.11 m
With width of 0.88 m, and for horizontal orientation, K values in Cost Estimating
Tables and Charts are obtained by interpolation;
Therefore:
Fp = 1.00
Fm = 4.00
B1 = 1.62
B2 = 1.47
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Therefore: F0BM = 1.62+ (1.47 )(4.00)(1.0)
= 7.50
Finally;
C0BM = C0pF0BM
C0BM = RM 89817.53
Pump 1 1 4,653.22
Pump 2 1 7,800.00
CPI Separator 1 89,817.53
Clarifier 1 20,364.96
Total 408,694.75
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10.3 Flare System
Gas flare which is known as a flare stack, is an elevated flare system found
accompanying the presence of oil wells, vented gases from blast furnaces, rigs,
refineries, gaseous water from chemical industries, natural gas plants, and landfills.
Also in case of an emergency situation, the flare system helps burn out the unwanted
and harmful gaseous. They are used to eliminate waste gas which is otherwise not
feasible to use or transport. They also act as safety systems for non-waste gas and are
released via pressure relief valve when needed to simplicity the damage on equipment.
They protect gas processing equipments from being over pressurized.
The chemical process used for flaring is a high temperature oxidation reaction to
burn combustible components which is hydrocarbons or waste gases from industrial
operations. In combustion, the gaseous hydrocarbon reacts with atmospheric oxygen to
form carbon dioxide (CO2) and water. Several by products formed will be carbon
monoxide and hydrogen. Efficiency of hydrocarbon conversion is generally over 98%.
Flare Knock-Out Drums are designed to remove hydrocarbon liquids from the main flare
relief gas effectively to prevent the possibility of liquid carryover and flaming rain from
the flare tip. Knock-out drum vessels and water seal located as close to the stack as
possible to avoid condensation in the flare header between the vessel and the flare.
The sizing of these knock-out drum vessels is generally based on the criteria
defined in API RP 521 considering residence time and knock-out velocity of the liquid
particles in the vapor flow. Since flare tips can handle small liquid droplets, the
allowable velocity in the drum may be based on that necessary to knock out droplets
from 300 microns to 600 microns in diameter; typically 450 microns.(Anon.2010)
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The propose of Knock-Out Drums is to avoid the accumulation of hydrocarbon
liquid, and will be equipped with instrumentation and control to monitor liquid level with
pump out or drain facilities.
Water Seals provide flash-back prevention in addition to enabling the upstream flare
system header to operate at a slight positive pressure at all times. This is because the
uses of an elevated flare in combination with another flare or with a flare gas recovery
system.
The vessel of Water Seal is fitted with a special saw-tooth dip leg and anti-
pulsation baffle to minimize pulsing. Filling rates will be sufficient to re-establish the seal
within 5 minutes if the liquid seal is broken (Anon,2010).
The Water Seal vessel may be equipped with an internal steam coil for cooling
purposes as required.
Elevated flare is the type that commonly used in refineries and chemical plants. It has
the larger capacities than ground flares. The waste gas stream is fed through a stack
from 32ft to over 320 ft tall and is combusted at the flare tip of the stack. While
combustion, it will produce CO2 and dust into air. The concentration of CO2 must be
compare with level of emissions Environmental Quality (Clean Air) Regulation 1978.
Elevated can utilize steam injection or air injection to made smokeless burning and with
low luminosity up to about 20% of maximum flaring load.
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Figure 10.6: Steam Assisted Elevated Flare System (source: A.L Ling, 2007)
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10.3.2 Flare System Plant Layout
Waste Ethylene
To wastewater
Vaporizer
Ethylene Treatment, CPI
Separator
Flare Knockout
Drum Pump
3 Elevated Flare
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10.3.4 Mechanical Design of Stack
Retentate stream from hydrogen recovery unit is sent to thermal fluid heater, to be burnt
along with natural gas. The thermal fluid heater used is the one used to heat up liquid
sodium for heat exchange. So, additional furnace or heating chamber will not be
needed in this section. The residues will be converted into H 2O and CO2 which is safe
to be released to atmosphere through stack.
The flue gas from the thermal fluid heaters will be dispersed into the air using a
stack that is made from carbon steel.
Assume:
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Calculation of rise of plume above the chimney, h
Using equation (8-7) from Environmental Engineering (Peavy et. al)
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Table 10.5: Equipment costing summary in flare system
Pump 1 1 4,500.00
Flare knockout drum 1 9,900.00
Flare water seal drum 1 9,900.00
Total 1,003,622.00
10.4 References
Tan Sri Ong Kee Hui, 2010. Environmental Quality (Sewage And Industrial Eftluents)
Regulations, 1979, viewed 22nd March 2011 from
http://faolex.fao.org/docs/pdf/mal2509.pdf
Anon, 2011.Corrugated Plate Interceptor, viewed from 25th March 2011 from
http://www.plateseparator.com/
Hammer and Hammer, 1996. Water and Wastewater Technology, Prentice-Hall, Inc
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A L Ling, 2007. Flare Selection And Sizing (Engineering Design Guideline), viewed 26th
March 2011 from ttp://kolmetz.com/pdf/EDG/ENGINEERING%20DESIGN%20
GUIDELINE-%20Flare%20Rev1.1.pdf
Anonymous, 2010. Water Seals and Knockout Drums, viewed 27th March 2011 from
http://www.gba.com/ancilliaries1.htm
10.5 APPENDICES
Appendix 10.1
To find K1;
To find K2;
K 2 0.5782 0.88 0.50
0.5905 0.5782 1.00 0.50
K2 = 0.5875
To find K3;
K 3 0.0632 0.88 0.50
0.1106 0.0632 1.00 0.50
K3 = 0.0992
To find C0p:
Log 10 C0p = K1 + K2 log 10 (13.11) + K3 [log10 (13.11)] 2
Log10 C0p = 4.0783
C0p = 11975.67
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