Industrial Effluent Treatment

System (IETS)

Food Processing Industry

Reference Journal

A Case Study on Waste Water

Treatment Plant, CETP (Common
Effluent Treatment Plant)
Wastewater Treatment for Food Processing
Industry
Palm Oil Industry
Standard B
Parameters
Unit Values Unit Values (mg/L)

pH - 7.9 - 7.9 5.5-9.0

Biochemical oxygen
mg/L 600 kg/m3 0.6 50
demand (BOD)

Chemical oxygen
mg/L 900 kg/m3 0.9 200
demand (COD)

Suspended solids mg/L 245 kg/m3 0.245 100

Oil and grease mg/L 25 kg/m3 0.025 10

BLOCK FLOW DIAGRAM IETS
SCREEN
CHAMBER
INLET CRIT
CHAMBER EQUALIZATION FLASH
TANK MIXER

CHEMICAL
OXIDATION SECONDARY PRIMARY
TANK CLARIFIER CLARIFIER
AERATION
TANK

PRESSURES SLUDGE
SAND FILTER HOLDING TANK

(TREATED EFFLUENT)

STORAGE TANK DECANTER

ACTIVATED
CARBON FILTER

SLUDGE
DRYING BED
(OUTLET)
TRANSFER TO RIVER
 PROCESS FLOW DIAGRAM IETS
SCREEN
CHAMBER CRIT
EQUALIZATION
FLOW METER CHAMBER
TANK
FLASH
INLET
MIXER

PRIMARY
CHEMICAL SECONDARY CLARIFIER
OXIDATION CLARIFIER
TANK PRIMARY
CLARIFIER

AERATION
TANK

PRESSURES
SAND FILTER SLUDGE
HOLDING TANK

(TREATED EFFLUENT)
STORAGE TANK

DECANTER

ACTIVATED
CARBON FILTER
(OUTLET)
SLUDGE
TRANSFER TO RIVER
DRYING BED
Mass Balance
Screening
pH Concentration BOD5 after removal
pH value = 7.9 = 0.50 x 600 mg/L
= 300 mg/L
COD Remaining BOD5 concentration
Remaining COD concentration = (600 – 300) mg/L
= 900 mg/L = 300 mg/L

BOD5
Proposed percentage BOD5 removal
= 50%
Maximum BOD5 loading
= 0.025 kg/m3 x 40 m3/d
= 1 kg/d
Mass loading BOD5 removal
= 0.50 x 1 kg/d
= 0.5 kg/d
Mass loading BOD5 after removal
= (1 – 0.5) kg/d
= 0.5 kg/d
Total Suspended Solids (TSS) Oil and Grease (O&G)
Proposed percentage TSS removal Remaining O&G concentration
= 40% = 25 mg/L
Maximum TSS loading
= 0.455 kg/m3 x 40 m3/d
= 18.2 kg/d
Mass loading TSS removal
= 0.40 x 18.2 kg/d
= 7.28 kg/d
Mass loading TSS after removal
= (18.2 – 7.28) kg/d
= 11.42 kg/d
Concentration TSS after removal
= 0.40 x 455 mg/L
= 182 mg/L
Remaining TSS concentration
= (455 – 182) mg/L
= 273 mg/L
Grit Chamber
pH BOD5
pH value = 7.9 Proposed percentage BOD5 removal
= 30%
COD Maximum BOD5 loading
Proposed percentage COD removal = 0.3 kg/m3 x 40 m3/d
= 20% = 12 kg/d
Maximum COD loading Mass loading BOD5 removal
= 0.9 kg/m3 x 40 m3/d = 0.30 x 12 kg/d
= 36 kg/d = 3.6 kg/d
Mass loading COD removal Mass loading BOD5 after removal
= 0.20 x 36 kg/d = (12 – 3.6) kg/d
= 7.2 kg/d = 8.4 kg/d
Mass loading COD after removal Concentration BOD5 after removal
= (36 – 7.2) kg/d = 0.30 x 300 mg/L
= 28.8 kg/d = 90 mg/L
Concentration COD after removal Remaining BOD5 concentration
= 0.20 x 900 mg/L = (300 – 90) mg/L
= 180 mg/L = 210 mg/L
Remaining COD concentration
= (900 – 180) mg/L
= 720 mg/L
Total Suspended Solids (TSS)
Proposed percentage TSS removal
= 45%
Maximum TSS loading
= 0.295 kg/m3 x 40 m3/d
= 11.8 kg/d
Mass loading TSS removal
= 0.45 x 11.8 kg/d
= 5.31 kg/d
Mass loading TSS after removal
= (11.8 – 5.31) kg/d
= 6.49 kg/d
Concentration TSS after removal
= 0.45 x 273 mg/L
= 122.85 mg/L
Remaining TSS concentration
= (273 – 122.85) mg/L
= 150.15 mg/L
Oil and Grease (O&G)
Proposed percentage O&G removal
= 90%
Maximum O&G loading
= 0.025 kg/m3 x 40 m3/d
= 1 kg/d
Mass loading O&G removal
= 0.90 x 1 kg/d
= 0.9 kg/d
Mass loading O&G after removal
= (1– 0.9) kg/d
= 0.1 kg/d
Concentration O&G after removal
= 25 mg/L x 0.90
= 22.5 mg/L
Remaining O&G concentration
= (25 – 22.5) mg/L
= 2.5 mg/L (comply discharge limit)
Flash Mixer
pH Total Suspended Solids (TSS)
pH increment after adding lime Remaining TSS concentration
= From 7.9 to 7.3 =150.15 mg/L
pH value
= 7.3 Oil and Grease (O&G)
Remaining O&G concentration
COD = 2.5 mg/L (comply discharge limit)
Remaining COD concentration
= 720 mg/L

BOD5
Remaining BOD5 concentration
= 210 mg/L
Primary Clarifier
pH COD
pH value Proposed percentage COD removal
= 7.3 (comply discharge limit) = 68%
Maximum COD loading
Oil and Grease (O&G) = 0.720 kg/m3 x 40 m3/d
Remaining O&G concentration = 28.8 kg/d
= 2.5 mg/L (comply discharge limit) Mass loading COD removal
= 0.68 x 28.8 kg/d
= 19.584 kg/d
Mass loading COD after removal
= (28.8 – 19.584) kg/d
= 9.216 kg/d
Concentration COD after removal
= 0.68 x 720 mg/L
= 360 mg/L
Remaining COD concentration
= (720– 489.6) mg/L
= 230.4 mg/L
BOD5
Proposed percentage BOD5 removal
= 80%
Maximum BOD5 loading
= 0.021 kg/m3 x 40 m3/d
= 0.84 kg/d
Mass loading BOD5 removal
= 0.80 x 0.84 kg/d
= 0.672 kg/d
Mass loading BOD5 after removal
= (0.84 – 0.672) kg/d
= 0.168 kg/d
Concentration BOD5 after removal
= 0.80 x 210 mg/L
= 168 mg/L
Remaining BOD5 concentration
= (210 – 168) mg/L
= 42 mg/L (comply discharge limit)
Total Suspended Solids (TSS)
Proposed percentage TSS removal
= 70%
Maximum TSS loading
= 0.150 kg/m3 x 40 m3/d
= 6.0 kg/d
Mass loading TSS removal
= 0.70 x 6.0 kg/d
= 4.2 kg/d
Mass loading TSS after removal
= (6.0 – 4.2) kg/d
= 1.8 kg/d
Concentration TSS after removal
= 0.70 x 150.15 mg/L
= 105.105 mg/L
Remaining TSS concentration
= (150.15 – 105.105) mg/L
= 45.045 mg/L (comply discharge
limit)
Aeration Tank
pH Total Suspended Solids (TSS)
pH value Remaining TSS concentration
= 7.3 (comply discharge limit) = 45.045 mg/L (comply discharge
limit)
COD
Remaining COD concentration Oil and Grease (O&G)
= 230.4 mg/L Remaining O&G concentration
= 2.5 mg/L (comply discharge limit)
BOD5
Remaining BOD5 concentration
= 42 mg/L (comply discharge limit)
Secondary Clarifier
pH
pH value
= 7.3 (comply discharge limit)
Oil and Grease (O&G)
Remaining O&G concentration
= 2.5 mg/L (comply discharge limit)
COD
Proposed percentage COD removal
= 80%
Maximum COD loading
= 0.230 kg/m3 x 40 m3/d
= 9.2 kg/d
Mass loading COD removal
= 0.80 x 9.2 kg/d
= 7.36 kg/d
Mass loading COD after removal
= (9.2 – 7.36) kg/d
= 1.84 kg/d
Concentration COD after removal
= 0.80 x 230.4 mg/L
= 184.32 mg/L
Remaining COD concentration
= (230.4 – 184.32) mg/L
= 46.08 mg/L (comply discharge
limit)
BOD5
Remaining BOD5 concentration
= 42 mg/L (comply discharge limit)
Total Suspended Solids (TSS)
Remaining TSS concentration
= 45.045 mg/L (comply discharge
limit)
Quantity Of Sludge Production And The
Volume Of Sludge Cake
Primary sludge: Wet sludge:
𝑀𝑝 = 𝜉 𝑥 𝑆𝑆 𝑥 𝑄 𝑀
𝑉=
1000. 𝑆
MP = Mass of primary solids kg/day
ξ = Efficiency of primary clarifier V = Volume of sludge produced
SS = Total suspended solids in m3/day
effluent kg/m3 M = Mass of dry solid kg/day
Q = Flow rate m3/day S = Solids content expressed as
decimal fraction
Secondary sludge: 1000 = Density of water kg/m3
𝑀𝑠 = 𝑌′ 𝑥 𝐵𝑂𝐷5 𝑥 𝑄

Ms = Mass of secondary solids

kg/day
Y’ = Biomass conversion factor
fraction of food (BOD5) incorporated into
biomass kg/kg
BOD5 = BOD5 removed by secondary
treatment kg/m3
Q = Flow rate m3/day
Characteristics of waste water, treatment
plant and sludge
Influent SS = 245 mg/L Sludge

Influent BOD = 600 mg/L Primary = 5.0 % solids

Effluent BOD = 42 mg/L Secondary = 0.75 % solids

Flow = 7000 m3/day Thickened = 4.0 % solids

Primary clarifier diameter = 14.23 m

Aerator volume = 5750 m3

MLSS in aerator = 2000 mg/L

Determine the mass of the primary solids
and the volume of the primary sludge
The area of primary clarifier: The mass of primary solids removed is
𝜋𝑑2 𝑀𝑝 = 𝜉 𝑥 𝑆𝑆 𝑥 𝑄
𝐴= 𝑘𝑔 7000𝑚3
4 𝑀𝑝 = 0.55 𝑥 0.245 3 𝑥
𝜋 14.23 𝑚 2 𝑚 𝑑
𝐴= 𝑘𝑔
4 𝑀𝑝 = 943.25
𝐴 = 159.04 𝑚2 𝑑

The overflow rate is

The volume of primary sludge is
7000 𝑚3 /𝑑 𝑀𝑝
= 44.01 𝑚/𝑑 𝑉𝑝 =
159.04 𝑚2 1000. 𝑆
943.25 𝑘𝑔/𝑑
𝑉𝑝 =
From Fig. 5-13 in textbook, the efficiency 1000 𝑘𝑔/𝑚3 𝑥 0.05
of the clarifier is 𝑉𝑝 = 18.87 𝑚3 /𝑑

SS = 55%
BOD = 31%
Determine the mass of the secondary solids
and the volume of the secondary sludge.
The food-biomass ratio: From Fig. 5-37 from textbook, the
The food consume in the aerator is: biomass conversion factor is 0.32
BOD in =(1.0 - 0.31) (600 mg/L) The mass of the secondary solids is
= 414 mg/L 𝑀𝑠 = 𝑌 ′ 𝑥 𝐵𝑂𝐷5 𝑥 𝑄
BOD out =effluent BOD 𝑘𝑔 𝑘𝑔
𝑀𝑠 = 0.32 𝑥 0.372 3 𝑥 7000 3
= 42 mg/L 𝑚 𝑚
BOD consumed in the aerator 𝑘𝑔
𝑀𝑠 = 833.28
= 372 mg/L 𝑑
= 0.372 kg/m3 x 7000 m3/d
=2 604 kg/d The volume of the secondary sludge is
𝑀𝑠
𝑉𝑠 =
The biomass in the reactor is 2.0 kg/m3 x 1000. 𝑆
5750 m3 = 11,500 kg 883.28 𝑘𝑔/𝑚3
𝑉𝑠 =
𝑘𝑔
1000 3 𝑥 0.0075
The food-biomass ratio is 𝑚
𝑉𝑠 = 117.77 𝑚3 /𝑑
2604 𝑘𝑔/𝑑
= 0.226 𝑑−1
11,500 𝑘𝑔
Determine the total mass of solids and the
total volume of sludge.
Total mass of solids: The total volume of the thickened sludge
𝑀𝑇 = 𝑀𝑃 + 𝑀 𝑆 (cake)
𝑘𝑔 𝑘𝑔 𝑀𝑇
𝑀𝑇 = 943.25 + 833.28 𝑉𝑡ℎ𝑖𝑐𝑘 =
𝑑 𝑑 1000. 𝑆
𝑘𝑔 1776.53 𝑘𝑔/𝑑
𝑀𝑇 = 1776.53 𝑉𝑡ℎ𝑖𝑐𝑘 =
𝑑 𝑘𝑔
1000 3 𝑥 0.04
𝑚
Total volume of sludge: 𝑚3
𝑉𝑡ℎ𝑖𝑐𝑘 = 44.41
𝑉𝑇 = 𝑉𝑃 + 𝑉𝑆 𝑑
𝑚3 𝑚3
𝑉𝑇 = 18.87 + 117.77
𝑑 𝑑
𝑚 3
𝑉𝑇 = 136.64
𝑑
Description
on Unit
Operation
Primary Treatment
Process Details Purpose Waste Treated

Placing static wedge • To protect pumps and

wire screen of 5mm other mechanical
Screening fineness on the initial equipment
Total Solid
Process flow of the wastewater. • Prevent clogging at valves
• Increase efficiency of IETS
plant
Installing aerated grit • Avoid abrasion of pumps
chamber causing and other mechanical
wastewater to spiral devices Inert dense material
Grit Chamber
and heavy particles to (Organic food particles)
settle to the bottom of
the tank.
The equalization basin • Helps in increasing the
collects the teated efficiency of the primary
wastewater from the and secondary treatment of
Equalization grit chamber and the IETS plant No components
Basin backwash water from removed
subsequent process
 Either alum or
ferrous sulphate is
added to the
• Cause rapid mixing to
wastewater before Reduce Turbidity and
promote good particle
Flash Mixer being mixed (1- Chemical Oxygen
collision for a good
3minutes) for Demand (COD)
coagulation.
flocculation and
coagulation process
to occur

Wastewater is allowed
to flow through the
clarifier causing the • The elongated clarifier slow Remove total suspended
lighter solids to float on the velocity of the solid (TSS), biological
Primary Clarifier the surface of the wastewater ensuring ample oxygen demand (BOD),
wastewater as scum and time for the solids to float or organic phosphorus and
the heavier solids to the settle in the clarifier. nitrogen, and heavy metals
bottom of the clarifier as
sludge.
 Secondary Treatment
Process Details Purpose Waste Treated

Wastewater is aerated with

• Provide sufficient air
air to make contact with
either through the surface
each other to remove
of the water or Reduce TSS, TDS,
dissolved gases (carbon
Aeration Tank introducing air bubbles at COD, and BOD
dioxide) and oxidize the
the bottom of the tank for level.
dissolved heavy metals (iron,
aerobic biological
hydrogen sulfide, and volatile
degradation
organic chemicals)
Function similar to primary • Remove the settleable
clarifier by allowing the suspended solids created
Secondary
activated sludge to settle in biological treatment TSS
Clarifier
down at the bottom of the processes (activated
tank. sludge)

Oxidants like hydrogen • Oxidise organic pollutants

peroxide, chlorine dioxide,
Chemical
chlorine gas, or peroxy
oxidation tank
acetic acid are added to the
wastewater
to a less harmful organic
Remove COD and
substances by converting
color components
them to carbon dioxide
and water
 Process Details Purpose Waste Treated

The wastewater is flowed

through the filter bed which
consist of a multiple layer of
Reduce turbidity and
Pressure Sand sands of varying sizes, water • Allow for the removal of the
suspended particles
Filters then pass through the layer of turbidity from the water
level
sands leaving behind the
suspended particles which
causes the turbidity

Adsorp microbial
Perform the adsorption of
contaminants, metals,
Activated Carbon certain organics which causes • To improve the appearance
nitrates, and other
Filter undesirable taste and odor in of the wastewater
inorganic
the water
contaminants.
Design for Structure and Tank
Unit Size Other Retention time
Information
Screener 0.45m x 1.8m 5 mm bar spacing -
Grit Chamber 0.45m x 1.8m x 9m Volume = 7.29𝑚3 90s
Equalization Basin 25m (diameter) x
- -
3m
Flash Mixer 1.35m x 1.8m x 6m Volume = 14.58𝑚3 60s
Primary Clarifier 14.23m (diameter) x
Volume = 318.18𝑚3 1.09hour
2m
Aeration Tank 21.4m (diameter) x
Volume = 5750𝑚3 4 hours
4m
Secondary Clarifier 14.23m (diameter) x
Volume = 318.18𝑚3 1.27 hr
2m
Chemical Oxidation
tank & Activated 3.2m (Diameter) x
- -
Carbon Filter 1.5m