CPE675: WASTEWATER ENGINEERING

SEMESTER: OCT 20 – FEB 21

ASSIGNMENT 3 (30%)

Company A is involved in manufacturing of fruit drinks and high quality of fruit juice
concentrated. The factory was operating for 1 shift of maximum for 8 hours on weekdays only.
Sources of wastewater generation is mainly from the washing process during preparation of
raw materials and cleaning of the equipment after mixing process. The combination of primary,
secondary, and tertiary treatment system was designed to treat 5 m3/day of raw effluent to
comply with Standard B. Summary of the Industrial Effluent Characterization Study (IECS) for
Company A can be referred in Table 1.

Table 1:Summary for IECS data

Parameter Value DOE Std. B
pH 3.7 5.5 to 9.0
Biological Oxygen Demand, mg/l 1800 <50
Chemical Oxygen Demand, mg/l 7448 <200
Total Suspended Solids, mg/l 168 <100
Oil & Grease, mg/l 12 <10
Color 628 <200

Currently, the wastewater from production line was treated by using industrial effluent
treatment system (IETS) as shown in Figure 1. The effluent from the production washing will
be channeled into an underground closed system equalization tank. Suitably size stainless
steel screen basket was installed to intercept and remove large solids before raw effluent enter
the system (EQ tank). For maintenance, all these solids need to be removed manually and
washed by operators. From there, it shall be fed at a constant rate to a Reaction tank.
After equalization tank, sodium hydroxide liquid, 10% (NaOH 10%) will be dosed in the
reaction tank using dosing pump and pH will be automatically controlled by pH controller.
Activated carbon powder will be dosed manually and mixed using static mixer before the
wastewater was transferred into reaction tank. pH in the reaction tank will be maintained in
range 7-8. Activated carbon powder solution was dosed as pretreatment chemical to removed
COD, color, and oil & grease. Then, pretreated wastewater will be transfer into aeration tank
(biological process).

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 Raw Effluent
Washing 5 m3/ day

Screening

Equalisation tank
AB600
Inline dosing
NaOH
Reaction tank

Aeration tank
Coagulant Inline
coagulation &
Flocculant flocculation
Sludge
Sludge Clarifier
holding tank

Filtrate Screw press Clear water tank

Sludge cake Carbon filter

To dispose “X” Final Discharge Comply to Standard B

Figure 1: Block flow diagram for current IETS

For the biological process, suspended growth biological treatment process, which is
return activated sludge process was selected in the process design. Microorganisms are kept
in suspension in the wastewater via the action of mixing and aeration. In the aeration tank,
biological flocs are continuously distributed to come into contact and to oxidize the organic
substances in the presence of oxygen. The activated sludge will be maintained in the system
for continuous and successful biological oxidation treatment of organic matter. The objectives
of activated sludge treatment are to obtain the maximum possible removal of organic
substances with the shortest possible time, and to produce flocculant biological flocs having a
good settling characteristic. Both are essential in controlling the secondary effluent quality.
After aeration tank, inline coagulation and flocculation process will be done using static
mixer before the partially treated wastewater going to the clarifier system. The dosing will be

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inline type where coagulant and flocculant will be injected inline before sent to clarifier. The
function of the chemical treatment is to increase the effectiveness of the separation of the
suspended solid to expedite the Solid-Water separation at further process solid liquid
separation process in clarifier. Metal base coagulant is used to destabilize the mixed liquor
particles; then a flocculant will be added to induce the flocs agglomerations. Excess organics
material or pollution will be removed by charge destabilization using coagulant. Currently, PAC
16% and Anionic Polymer was used as coagulant and polymer. For the pH adjustment NaOH
10% was used.
Then, the pretreated wastewater will be channeled into clarified tank. Solid and liquid
separation was occurred due to gravity factor. Waste activated sludge (WAS) will be
transferred into sludge tank for further undergo dewatering process by using screw press.
Return activated sludge (RAS) will be transferred into aeration tank. Supernatant will be stored
in the clear water tank before further process in the carbon filter.
The treated water can be further polished by using Carbon Filter before discharge to
the final discharge point. This filter can remove any carry over suspended matter and
remaining residue of organic compound. Figure 2 shows a summary of mass balance for the
current IETS provide by the previous IETS consultant.
After 6 months been operated, the IETS started to get in trouble. The main problem
that they are facing such as:
1. Overflow from stainless screen basket cause pump and flowmeter malfunction due
to chocking with unwanted material.
2. High BOD, COD and color removal after 6 hours of aeration in the aeration tank.
3. Sludge carries over in the clarifier tank and it will be worst on Monday because
IETS plant was shut down during the weekend.
4. Odor and COD concentration increase after clarifier tank.
5. Carbon filter easily gets chocked.

As a new IETS Engineer in charge for this IETS, you are given tasks to verify the
design of the current IETS. You need to prepare a complete proposal to be submitted to
Environmental Regulatory Compliance Monitoring Committee (ERMC) for the improvement
purpose to ensure compliance with Standard B, Environmental Quality (Industrial Effluent)
Regulation 2009. The proposal should include:
1. Detail explanation on how to prevent the main problem that the IETS currently
facing.
2. Detail comment on current IETS design including;
a. Process and unit operation selection
b. Calculation on tank sizing

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 c. Selection of chemical dosing such as type of coagulant, flocculant,
operating condition including pH and chemical dose.
3. Detail information for the proposed treatment process including;
a. Process description of the proposed treatment process includes the
function of each unit operation and chemical or any related item proposed
in the treatment process.
b. Block diagram of proposed treatment process for IETS.
c. Calculation of mass balance for each unit operation. Selection on
percentage removal must be cited from valid references. The summary
of mass balance for overall unit operation should be presented in block
flow diagram.
d. Design calculation of each unit operation proposed in IETS
e. Detail description of selection and calculation process of chemical dosing
such as type of coagulant, polymer, operating condition including pH and
chemical dosage.
f. The process flow diagram (PFD) of proposed treatment process
(inclusive pump, compressor, blower, etc.).

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 Q = 5 m3/day Q = 5 m3/day
3
Q = 5 m /day % mg/L kg/day % mg/L kg/day
mg/L kg/day Removal Removal
COD 7448 37.24 COD 70 2234 11.17 COD 95 112 11.17
BOD 1800 9 BOD 60 720 3.6 BOD 95 36 3.6
TSS 168 0.84 TSS 0 168 0.84 TSS 90 17 0.84
O&G 12 0.06 O&G 50 6 0.03 O&G 20 5 0.03
Reaction Aeration Clarifier
Equalization Color = 628 ADMI Color 70 188 ADMI Color 60 75 ADMI 3 Supernatant
Tank Tank Tank 4m
3 3
3m
3
0.4 m 8m

Q = 5 m3/day
% mg/L kg/day
Removal
Screw Press Sludge COD 40 67 0.34
Filtrate water 0.5 m3/day Tank BOD 40 22 0.11
3 TSS 60 7 0.03
1m
O&G 0 5 0.02
Color 0 75 ADMI

Clear Water
Tank
Sludge disposal 3
1m

Carbon
Filter
5 m3/hr

Q = 4.5 m3/day
% mg/L kg/day
Removal
COD 50 34 11.17
BOD 50 11 3.6
TSS 20 5 0.84
O&G 0 5 0.03
Color 90 8 ADMI

‘X’ Final Discharge

Figure 2: Provide mass balance for the current IETS