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1.

INTRODUCTION
This manual contains all information for operating and maintaining the
wastewater treatment plant at Preferences Trading Industries Sdn Bhd.
The wastewater treatment plant is designed to provide an optimal pollutant
removal. This can only be reached when the instruction given in this manual are
taken care off. For detailed information concerning the equipment installed,
please refer to the relevant chapters/catalogue.
This manual also contains instruction about equipment routine inspection,
analysis of certain parameters on varied time intervals and to maintain a proper
record of these. To meet the required effluent quality, it is absolute important that
these data are controlled and recorded.

1.1 DESIGN CRITERIA


1.

Source of effluent

: E-Waste

2.

Design Capacity

: 3.93 m3/Hr

3.

Operating Hours

: 8 hrs/day

4.

Treated Water Requirement


PH
Cyanide
Lead
Suspended Solid
Oil & Grease
COD
BOD

5.

DOE Std B
5.5 9
< 0.1 ppm
< 0.5 ppm
< 100 ppm
< 10 ppm
< 100 ppm
< 50 ppm

Treatment Method.
This is the combination of cyanide destruction treatment system and
continuous chemical precipitation treatment system. The pH of the waste
water is adjusted with acid and caustic and the pollutants are removed by
adding various type of coagulants and flocculating agents. The sludge is
removed through filter press.

2.0

EQUIPMENT SPECIFICATIONS
1. CN HOLDING TANK
Capacity
: 10 m3
Material
: FRP
Quantity
:2
2. CN DESTRUCTION TANK
Capacity
: 2.5 m3
Material
: FRP
Quantity
:2
3. EQUALIZATION TANK
Capacity
: 15 m3
Material
: FRP
Quantity
:1
4. CHEMICAL REACTION TANK
Capacity
: 3.5 m3
Material
: FRP
Quantity
:1
5. CHEMICAL TANK
Capacity
: 250 Liter
Material
: FRP
Quantity
:3
6. CHEMICAL TANK
Capacity
: 500 Liter
Material
: FRP
Quantity
:2
7. CLARIFIER
Capacity
Material
Quantity

: 2 m3
: FRP
:1

8. FINAL PH ADJUSTMENT TANK


Capacity
: 1 m3
Material
: FRP
Quantity
:1
9. BREAK TANK
Capacity
Material

: 1 m3
: FRP

Quantity
:1
10. SLUDGE THICKENER TANK
Capacity
: 1 m3 (Conical Bottom)
Material
: FRP
Quantity
:1
11. CN TRANSFER PUMP
Super Magnetic Sealless Pump
Model
: SMF 25180-3
C/w 0.18kw, 3ph/415V/50Hz motor
Material
: FRPP
Capacity
: 2 m3/hr@5.5 m
Inlet/Outlet
: 1
Quantity
:4
12. CHEMICAL TREATMENT FEED PUMP
Ebara Stainless Steel Centrifugal Pump
Model
: CDX 70/05
C/w 3ph/415V/50Hz motor
Material
: Stainless steel
Capacity
: 4 m3/hr@6 m
Inlet/Outlet
: 1.25
Quantity
:2
13. CHEMICAL DOSING PUMP
Model
: Husky 205-D12096
Material
: PP Wetted Parts & Santoprene Diapharagm
Port Size
: X
Quantity
:9
14. DESLUDGE PUMP
Model
: Husky 1590-DBCGGG
Material
: Aluminium Wetted Parts, Geolast Ball & Diapharagm
Port Size
: 11/2 X 11/2
Quantity
:1
15. FILTER PRESS FEED PUMP
Model
: Husky 1590-DBCGGG
Material
: Aluminium Wetted Parts, Geolast Ball & Diapharagm
Port Size
: 11/2 X 11/2
Quantity
:1

16. CARBON FILTER FEED PUMP


Ebara Submersible Pump
Model
: Best 1 SG
C/w 0.25kw, 1ph/220V/50Hz motor
Material
: Stainless Steel 304
Quantity
:2
17. DRY PIT PUMP
Ebara Submersible Pump
Model
: Best 1 SG
C/w 0.25kw, 1ph/220V/50Hz motor
Material
: Stainless Steel 304
Quantity
:1
18. CN DESTRUCTION TANK MIXER
3 ph/415V/50Hz motor
Stainless steel shaft & Propeller
Output Speed
: 900 rpm
Quantity
:2
19. CHEMICAL REACTION TANK MIXER
3 ph/415V/50Hz motor
Stainless steel shaft & Propeller
Output Speed
: 900 rpm
Quantity
:2
20. CHEMICAL REACTION TANK MIXER
3 ph/415V/50Hz motor
Stainless steel shaft & Propeller
Output Speed
: 120 rpm
Quantity
:1
21. TFLOC TANK MIXER
3 ph/415V/50Hz motor
Stainless steel shaft & Propeller
Output Speed
: 120 rpm
Quantity
:1
22. AIR BLOWER
Taiko Roots Blower
Model
: SSR50
C/w 2.2kw, 3ph/415V/50Hz motor
Capacity
: 1 m3/min@ 4 m Head
Quantity
:1

23. FILTER PRESS


Brand
Press Type
Model No
Press Volume
Quantity

: Well Filter Press


: 500 mm X 500 mm X 17 chambers X 32 mm (Manual)
: KP50C104/MOL5 (Manual)
: 104 liters
:1

24. PH CONTROLLER
Model
: D1C - pH
Signal Input
: mV from sensor
Resolution
: 0.01 pH
Power
: 230V, 50Hz, 0.05A
Measuring Range : 0 14 pH
Quantity
:5
25. ORP CONTROLLER
Model
: D1C ORP
Signal Input
: mV from sensor
Resolution
: 1 mV
Power
: 230V, 50Hz, 0.05A
Measuring Range : 0 1000 mV
Quantity
:2
26. DISCHARGE FLOWMETER
Brand
: Burkert
Model
: 8046
Supply
: 24VDC
Quantity
:1
27. CARBON FILTER
Capacity
: 3.3 cuft
Quantity
:3

3.0 OPERATION METHOD


3.0 CYANIDE DESTRUCTION PACKAGE
3.0.1

Function

This process involves the addition of Oxidising agents and chemicals to oxidize
cyanide into cyanate and ultimately to carbon dioxide and nitrogen.
Destruction of cyanide by chlorination may be accomplished by direct addition of
oxidizing agents exp. Sodium hypochlorite plus sodium hydroxide to the waste
water. The hypochlorite added or produced oxidizes cyanide to cyanate.
Oxidation of cyanide to cyanate is accomplished most completely and rapidly
under alkaline conditions at pH 10.5 or higher, and this cyanide treatment process
is often termed alkaline chlorination. At the same time, Oxidising agent is added
until ORP becomes more positive than about +300 mV. An oxidation period of 30
minutes to 2 hours is usually allowed. To avoid solid cyanide precipitates which
may resist chlorination, the waste water should be continuously mixed during
treatment.
3.0.2

Operation

Make sure that the pH & ORP Controller, pH-1 pH-2 and ORP 1,
ORP-2 are functioning.

Make sure all Chemical Tank (TOxid, TALK) have sufficient


chemicals for operation.

Switch all of the relevant dosing pumps to AUTO.

Switch all the relevant mixers (MX-1, MX-2) to ON position.

Select CN Transfer Pump to be operated by switching selector switch


of the selected pump to ON position.

Ensure the Inlet and Outlet Valve of the selected pump is open.

The pump is interlocked with Level Switch in the CN Holding tank.


The Level Switch is actuated by the water level in the tank to repeat
the pump ON signal at high level and pump OFF at low level
automatically.

Make sure that all mixers are operating.

The control of dosing pumps may change to manual instead of auto


depending on the wastewater condition.

Weekly counter changing of transfer pump operation is recommended.

3.0.3

CHEMICAL PREPARATION

1. T OXID 100 % CHEMICAL


2. TALK - 20 % CHEMICAL + 80 % WATER
3.0.4

Maintenance

For the maintenance of Dosing Pump and flow meter, please refer to the
individual manuals.

3.1 CHEMICAL PRECIPITATION PACKAGE


3.1.1

Function

This process involves the addition of chemicals to alter the physical state of
dissolved and suspended solids and to facilitate their removal by sedimentation.
Coagulation and Flocculation is a process, in which chemicals which promote the
aggregation of suspended/ dissolved solids into particles large enough to be
separated by sedimentation. The effectiveness of a particular coagulant varies in
different applications, and in a different application every coagulant has an
optimum concentration and pH range in this process.
For full effectiveness, wastewater requires initial rapid mixing to disperse
thoroughly the applied chemicals so that they can react with suspended and
colloidal solid uniformly.
Inclined Plate in the settler is useful in prevent/ minimize carry over of lighter
floc. By installing the inclined plate in the settler, suspended solids will be settled
more rapidly to the bottom of the tank, than in an open channel flow system
(clarifier without inclined plate). This is because the inclined plate providing more
contact surface for the adherence of particles and hence separate the particles
from the carrier flows. These particles will be then settled to the tank bottom by
gravitational force and forms a layer of sludge, which will be than pump to
Dewatering Package.

3.1.2

Operation

Make sure that the pH Controller, pH-3 pH-4 and pH-5 are
functioning.

Make sure all Chemical Tank (TAD, TA 10, TALK, TFLOC) have
sufficient chemicals for operation.

Switch all of the relevant dosing pumps to AUTO.

Switch all the relevant mixers (MX-3, MX-4, MX-5, MX-6, MX-7) to
ON position.

Select EQ Feed Pump to be operated by switching selector switch of


the selected pump to ON position.

Ensure the Inlet and Outlet Valve of the selected pump is open.

The pump is interlocked with Level Switch in the Equlization tank.


The Level Switch is actuated by the water level in the tank to repeat
the pump ON signal at high level and pump OFF at low level
automatically.

When the tank is in high level, Level Switch will trigger the high level
alarm and switch ON the Feed Pump. All mixers and dosing pump in
this package will automatically ON and operated according to the
pre-set value.

Make sure that all mixers are operating.

The control of dosing pumps may change to manual instead of auto


depending on the wastewater condition.

Weekly counter changing of transfer pump operation is recommended.

3.1.3

CHEMICAL PREPARATION

3. TAD 20 % CHEMICAL + 80 % WATER


4. TA10 100% CHEMICAL
5. TALK - 20 % CHEMICAL + 80 % WATER

6. TFLOC APPR0X 70 g OF CHEMICAL POWDER + WATER.

3.1.4

Maintenance

For the maintenance of Dosing Pump and flow meter, please refer to the
individual manuals.

3.2 SLUDGE DEHYDRATION


3.2.1

Function

The purpose of having a Sludge Thickener after the clarifier is to further


concentrate the solids and thereby reduce the disposal and handling cost of
sludge. The sludge will be settled by gravitation force in Sludge Thickener and is
then pumped to the Filter Press by Filter Press Feed Pump.
In Filter Press, dewatering is achieved by forcing the water from the sludge under
high pressure. The filter press consists of a series of rectangular plates, recessed
on both sides, that are supported face to face in a vertical position on a frame with
a fixed and movable head. A filter cloth is hung or fitted over each plate. The
plates are held together with sufficient force to seal them so as to withstand the
pressure during the filtration process. Hydraulic rams are used to hold the plates
together.
Sludge is pumped to the space between the plates and pressure is applied to force
the liquid through the filter cloth and plate outlet port. The plates are then
separated and the sludge is removed. The filtrate is returned to the equalization
sump and the dried sludge will be collected in sealed container for final disposal.

3.2.2

Operation Method

In a fix interval period, or when sludge is needed to be pumped out


from the Sludge Thickener. Manually turn the Filter Press Feed Pump
to ON position.

Pressure will slowly increase when the filter press is filling up with
sludge. Eventually the pressure will be built up to a limit where the

diaphragm pump is unable to run. Manually turn OFF the switch


when the Filter Press is full.
Proceed to remove the sludge cake from the filter plates.

3.2.3

Maintenance

The cloth of Filter Press must be clean with Water Spray Gun periodically.

3.4

CARBON FILTER

3.4.1 Introduction
The purpose of Carbon Filter is to remove Chlorine and Organic Impurities from
the water. Although the filter also accomplishes filtering of turbidity, it is
incidental to the prime purpose of the filter. Greater amount of turbidity in the
inlet water can decrease the effectiveness of the carbon, shortening its useful life.
Other types of filters upstream of the Carbon Filter should remove turbidity.
3.4.2 Initial Start-Up
New Activated Carbon is recommended to be soaked for at least 24 hours before
backwashing. During initial start-up Carbon Filter shall be backwashed, until the
backwash water is clean before putting to rinse and then service.
3.4.3 Operation
When the Filter is in operation, water enters the top of the Filter and is evenly
distributed over the media bed. As it flows through the bed, chlorine and
impurities are trapped at the top of the bed while organic are absorbed on the
carbon granules throughout the entire bed. The differential pressure across the
Carbon Filter bed is not a good indicator for the need to backwash. The Carbon
Filter should be backwash every day to help keep it sterile.
Carbon Filter media does not have an unlimited life. Eventually the granules will
no longer adsorb organic and chlorine to a useful degree. When this occurs, the
carbon must be replaced. Generally, a carbon bed may be expected to be useful
for approximately 6 to 12 months. High levels of chlorine and organic can reduce
filter media life and low levels can increase the life. The best way to determine

the condition of the carbon bed is to periodically check the filter effluent for
excessive signs of chlorine and organic.

3.4.4

Backwashing of Carbon Filters

When performing the backwashing for the Carbon Filter, the following steps are
taken:
Interchange the inlet hose to outlet position and it with outlet hose to inlet
position.
Ensure there is sufficient water in the Break Tank
Ensure the discharge valve pipeline divert to EQ Tank
Press the ON button to initiate the CF Pump. Check until the backwash water
is clear
When the backwash is completed, Off the CF pump and change back the
Inlet/Outlet hose and valves back to normal position.

FOR THE MAINTENANCE OF DOSING PUMP AND FLOW METER, PLEASE


REFER TO THE INDIVIDUAL MANUALS

4.0

THEORY OF OPERATION
COAGULATION FEED THEORY AND OPERATION
Very small particles below 10 um in size cannot be separated simply by
sedimentation because of their very slow settling velocities. The stability of these
fine suspensions is due to electrostatic forces and it is necessary for these to be
neutralized to encourage flocculation into assemblages of small particles which
will precipitate more readily.
Coagulant are added to neutralize the charges on the particles which then
agglomerate to form a floc with improved settling characteristics.
The floc mass is spongy and because of its large surface area, absorbs dissolved
matter from solution; therefore it also assists in the removal of colour, turbidity,
organic matter and bacteria from solution.
The selection of suitable coagulant, the correct dosage and the optimum pH for
treatment depend upon several factors such as the effluent requiring treatment, its
temperature and other limitations on discharge and also on the equipment
available.

POLYMER FEED THEORY AND OPERATION


Polymers when dissolved in water containing finely coagulated particles will cause
further agglomeration of suspended solids to form large flocs.
Because of the flocculation ability, the polymer when applied in the flocculation tank will
speed up the sedimentation process i.e. the settling becomes faster in both the plate settler
and in the sludge holding tank. It improves the thickening and dewatering process in the
filter press process.

APPLICATION
Before carrying out the operation trials, it is advisable to determine the most suitable
polymer for the job by laboratory jar tests. Specific features such as optimum dilution
rate, amount of chemical dosage, the duration and intensity of stirring/mixing process are
pre-determined. Multiple polymers if necessary can also be used.
PH ADJUSTMENT
PH treatment is basically concerned with acidic or alkaline treatment. Acid and alkaline
are basically the converse of each other. When acid is neutralized with caustic, the
Hydroxyl ion (high pH) of an alkali will treat the hydrogen ions of acids (low pH) to
form water. The acid anion and the caustic cation will form a salt e.g. NaCl.
The choice of alkaline to be used for neutralization is dependent upon local conditions
and the actual requirements of the alkaline. Lime is used for waste which required
extension treatment, but lime preparation is inconvenience and sludge volume is large as
compared to caustic soda which is relatively easy handle and it therefore recommend for
low requirement.

5.0TROUBLESHOOTING
ITEMS TYPE OF PROBLEMS
1
No Floc

Transfer Pumps not


working

ORP & PH Controller


Malfunctions
Filter Press Malfunctions
Chemical Dosing Pump
Malfunctions

4
5
6

Desludge Pump
Malfunctions

Carbon Filter Blockage

REMEDY
- Check all the chemical pump is
working or not.
- Chemical already prepared and dosing
in sequence.
- Check the pH setting/reading is correct
or not, if pH reading is not correct,
please perform calibration on the pH
probe. Preferable perform calibration
once a month. (Procedure refer
catalogue)
- Check the switch is On or not.
- Level of the sump is too low
- Check the pump float switch
- Others refer pump catalodge
- Refer controller manual.
-

Refer operating manual


No air supply.
Purge out water in the air line.
Refer operating manual
No air supply.
Purge out water in the air line.
Refer operating manual
Change the granular carbon inside the
column. (Recommendation to change 3
6 months depend on waste
characteristics)

6.0 SAFETY PRECAUTIONS


6.1 PERSONAL SAFETY PRECAUTIONS
These summarized cautions and safety instruction should be communicated to all
personnel working on and/or around the Wastewater Treatment Plant. Guidelines
below should be supplemented with formal safety training in the safe handling of
all chemicals. Appropriate safety equipment should be available.
6.1.1

Severe Personal Injury or Death May Occur

If in doubt, STOP and ask for help

NEVER add water to acid or mix strong acid with strong caustic. A
violent reaction occurs
NEVER add water or acid to strong caustic. A violent reaction
occurs.
NEVER reach into energized electrical panel. Electrocution may
result
ALWAYS keep hands, loose clothing and long hair away from
rotating machinery
6.2 CHEMICALS PRECAUTIONS
WARNING ALWAYS wear safety goggles and full face
shields, use rubber gloves and wear chemical resistant
aprons and boots when handling chemicals, charging tanks,
checking chemicals feed connections, taking samples, etc.
WARNING

ALWAYS be sure that pipe and tubing is depressurized


before disassembly. When reassembling connections,

ensure that all connections are tight. Re-pressurize slowly


to avoid spills and leakage. Be especially careful around the
metering pumps.
DANGER

NEVER ADD WATER TO CONCENTRATED ACID OR


MIX
STRONG
ACID
DIRECTLY
WITH
CONCENTRATED CAUSTIC SODA.
A rather violent reaction will occur with the release of a
great deal of heat. Such reaction could cause severe injury.

WARNING

ALWAYS reads and follows instruction on the labels of


chemical containers.
NEVER mix chemicals together without knowing what the
result will be.

WARNING

NEVER ADD WATER TO CAUSTIC SINCE


EXCESSIVE HEAT WILL BE GENERATED. ALWAYS
add caustic to water SLOWLY

WARNING

NEVER ADD WATER TO ACID SINCE EXCESSIVE


HEAT WILL BE GENERATED. ALWAYS add acid to
water SLOWLY

6.3 ELECTRICAL PRECAUTIONS


DANGER

ALWAYS makes sure that electrical power has been


disconnected before any electrical panel or junction box.
Electrical troubleshooting or repair should perform only by
trained personnel.

6.4 MECHANICAL COMPONENTS PRECAUTIONS


DANGER

ALWAYS keeps hands, loose clothing, long hair away from


rotating shafts or pumps and mixers.

WARNING

ALWAYS open and close valves slowly to avoid water


hammer, which may cause damage to connections or
equipment.

CAUTION ALWAYS makes sure that settings of liquid level floats are sufficient to
avoid cavitation of the pumps.

7.0 DRAWINGS

8.0

EQUIPMENT MANUAL AND CATALOGUE

OPERATION MANUAL
3.92 m3/Hr CHEMICAL
WASTE WATER TREATMENT
SYSTEM
FOR

PREFERENCES TRADING
SDN BHD

BY
TERTIB ALAM ENTERPRISE