Industrial Wastewater Treatment Plant

Chemical Biological – System DAF –Technology

100 m3/day

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RAW WASTEWATER CHARACTERISTICS

Daily flow 100 m3/d

Hourly flow 6.25 m3/h

PH 8.5 -

COD 5000 mg/l

BOD 2500 mg/l

TSS 2500 mg/l

Oil and grease 300 mg/l

Effluent Quality
The treated effluent quality shall meet the requirements of the Egyptian law no.93/62
modifiedbe decree 44/2000 for discharging industrial waste water to public sewer low
limits
Law limit Accepted level

PH 7-9.5 7-9.5

COD 1100 mg/l 990

BOD 600 mg/l 540

Total suspended solids 800 mg/l 720

Oil and Grease 100 mg/l 90

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Treatment Steps:

The treatment steps of the offered IWWTP are as follows:

 Coarse screen 5 m3/hr.

 Collecting pit 10 m3
 1st Pumping station 5m3/hr. @3 bar (1 on duty / 1 standby)
 Balancing tank 25m3
 2nd Pumping station 6.25 m3/hr. @3 bar (1 on duty / 1 standby)
 Chemical DAF One
 Aeration Air blowers 750 m3/hr. (1 on duty / 1 standby)
 Break tank 5m3/hr.
 3rd Pumping station 15m3/hr. @3 bar (1 on duty / 1 standby)
 High rate sedimentation unit One
 Chlorination tank 6 m3
 Multimedia filter 6.25 m3 /hr. (1 on duty / 1 standby)
 Sludge holding tank 10 m3
 Screw press unit 2m3 hr. 1 duty

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PROCESS CALCULATIONS:
Process Calculations:
 Collection Pit:
Effective Volume: 10 m3
Retention time: 2 hr.
 Equalization tank:
Effective Volume: 25 m3
Retention time: 5 hr.

 Aeration tanks:
Effective Volume: 100 m3
Retention time: 24 hr.

 Chlorination tanks:
Effective Volume: 6 m3
Retention time: 1 hr.
 Sludge Holding tank:
Effective Volume: 10 m3
Retention time: 24 hr.

Air blowers for Balancing & sludge holding tanks: 1 on duty + 1 standby 750m3/hr. @ 500 mbar

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 PROCESS DESCRIPTION
PROCESS DESCRIPTION:

 Screening (Coarse Screen):

The wastewater influent then flows through a self cleaning coarse screen with fine spacing which
removes large solids such as debris, papers, … etc and prevents them from entering the plant. Arc
screen has greater capacity than a flat screen as the bar curvature of the screen offers a higher
screening area for a given width of channel. The pre-assembled bar screen is equipped with two
rakes set on a common central shaft directly coupled to the drive unit. Their rotating through 360
degrees ensures rapid front removal of the solids.

 Equalization (Balancing):
Wastewater effluent from inlet lifting sump will be pumped to the equalizing tank via inlet lifting
pumps in order to homogenize the wastewater effluent in terms of pollution and hydraulic load
and to gurantee the reliability and stability of the process.
The pH value is adjusted inside the equalizing tank via injecting of an acid or alkali based on the
pH controller feedback signal. The balacing tank is aerated at the bottom through coarse bubble
air diffusers to avoid any anaerobic conditions

- Chemical Treatment System:

 Dissolved Air Floatation Unit (DAF):

Dissolved air floatation is a process used to separate suspended solids and O&G particles from
the wastewater effluent resulting in production of concentrated sludge. This way it is possible to
separate particles from water that have high denisty.
DAF system incorporates one chamber to perform the following functions:
 Coagulation.
 Flocculation.
 Clarification.
Fine small air bubbles stick to the particles & flocs causing them to float as their density less than
water. This way; it is possible to separate particles from water that have higher denisty. This
results in the floated material to be gathered in a scum layer at the surface of the solution.

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 Aeration tanks:
The chemically treated effluent flows by gravity to the biological treatment stage
The mixture must be agitated to prevent settlement and aerated to supply oxygen for the
respiration of the microorganisms air blowers delivering via an air manifold to fine diffusers
which release the air near the bottom of the aeration tank.
the organic material from the wastewater and multiply it to greater numbers resulting in excess
activated sludge that needs to be occasionaly disposed.

 Biological Daf (HAIGH RATE SEDIMENTATION WITH LAMELLA ASSEST):

The liquor containing biomass enters the settling tank where the sludge is settled and the clear
effluent overflows over the V-notch weirs to the effluent discharge.
The separated sludge at the bottom of the settling tank will be pumped to sludge dewatering
system while the clarified treated effluent will be sent to chlorination tank.

 Chlorination tank:
This tank is considered as a balancing tank between the secondary and tertiary treatment stages.
Any harmful bacteria remaining in the treated effluent will be killed through disinfection by
dosing of Sodium Hypochlorite solution with sufficient contact time.

 Multimedia filters:
Chlorinated water will be pumped from the chlorination tank to the multimedia filters through
Multimedia filters feed pumps. Multimedia filters will remove suspended solids and reducing the
remaining settable organic loads before entering the activated carbon filters.

 Sludge Holding Tank:

The chemical and biological sludge will be collected in the sludge holding tank to be thickened &
stabilized. Bottom sludge in settling tank is pumped to sludge holding tank via RAS/WAS pumps
where RAS portion is recycled to activation zone and WAS portion is pumped to excess sludge
holding tank which is aerated by coarse bubbles air diffusers for further sludge stabilization and
thickening where sludge conditioning takes place by addition of polyelectrolyte to enhance the
efficiency of dewatering process.

 Screw press:
A screw press is used for dewatering of sludge to 18-25% solid content. Dewatered sludge will be
packed for final disposal.

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 SCOPE OF WORK AND SUPPLY

SCOPE OF WORK & SUPPLY:

-Scope of Work:

The scope of work includes the following:

 Process design and engineering

 Inspect civil works during handover for accordance with basic design requirements.
 Supply & installation of all inside battery limits equipment, fittings, interconnecting piping,
valves, flanges, spreader bars.
 Installation & commissioning & startup.
 Testing & inspection.
 Spare parts for two years (optional).
 Pre-commissioning, commissioning & start up spare parts.
 Package process and mechanical performance guarantee.
 Submission of engineering documents (O&M manuals & drawings).
 Guarantee of the plant equipment against manufacturing defects for 18 months from delivery
date or 12 months from operation date whichever come early.
 Providing after sale services.

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- Scope of Supply:

Sr. Item Unit Quantity

Primary treatment
1 Coarse screen No. 1
2 Collecting pit 10 m3 No. 1
3 Pumping station 6.25m3/hr @3 bar (1 on duty / 1 standby) No. 2
4 Balancing tank 25 m3 No. 1
Secondary treatment
Coagulant dosing set includes:
 Two dosing pumps.
1 L.S 1
 One dosing tank
 One dosing mixer
Flocculent dosing set includes:
 Polymer preparation unit
2 L.S 1
 Two dosing pumps.
 One dosing mixer
3 Flocculation skid No. 1
4 Dissolved Air Flotation (DAF) System L.S 1
Biological treatment 100 m3
1 Aeration tank. 100 m3 1 1
2 Air blowers 750m3/hr. No. 2
3 fine bubble air diffusers 7 ً L.S 200
Sludge treatment
1 Sludge holding tank 10m3 No. 1
2 Screw press unit No. 1
Piping
1 Interconnecting pipework, valves & fittings L.S 1
Electrical works
1 Main control cabinet No. 1
2 PLC L.S 1
3 HMI L.S 1
4 Power cables L.S 1
5 Control cables L.S 1
6 Earthling L.S 1

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Exclusions:

The following is not included in our scope of work:

 All items of equipment & scope not specifically included herein.
 Civil works construction.
 Air conditioning, firefighting, lighting & ventilation.
 Tie-connection outside battery limits
 Raw water for commissioning & handing over.
 Sludge cake disposal.
 All equipment or pipework outside termination point
 Third party inspection cost.
 Technicians for operating the plant after startup.
 Incomin power supply to the main power distribution panel.

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 TECHNICAL SPECIFICATIONS

TECHNICAL SPECIFICATIONS:

fine Curved Screen:

Type curved screen
Flow 6.25 m3/hr
Spacing 15 mm
Material Stainless Steel 304l
Qty One (duty)
Cleaning manual

Lifting pumps:
Brand Ebara, LOWARA
Type Submersible pump
Capacity & pressure 15 m3/hr. @3 bar
Material of shaft & impeller Stainless steel 304
Material of impeller Cast Iron
Power 1 kw
Origin Europe
Qty. (1 duty/1 standby)

Balancing Tank
CONSTRUCTION CONCRETE TANK
VOLUME 25 m3
Inlet 1st pumping station
Outlet 2ND pumping station
Retention time 6 hours

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Dissolved air flotation Unit:
Material of construction Steel 304l
Dimension 3.5 m * 2.1 m * 2.6 m (L*W*H)
Inlet/outlet size 3 inches
Sludge volume 800 liters
Sludge outlet size 3 inches
Flotation Rate 0.5m3/hr. up to 0.6 m3/hr.
Origin Local
Qty One

PH MEASURING SYSTEM (pH Controller)

QUANTITY One
TYPE ELECTRODE PIN
SIZE ¾ INCH
INLET READING ONLINE
OUTLET READING ONLINE

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Pipe Flocculator

Dimension 2000 cm * 60 cm * 80 cm
flow rate 6.5m3/ hr.
Flange size/diameter 2 inch/2 inch
Total length of tube 30:40 m
No of levels 6
Material Body: Stainless Steel 304
Frame: Stainless Steel 304

DAF Surface Skimmer:

Skimmer travel speed 15 rpm
No. of skimmer flights 5
Spacing between flights 80 cm
Materials of skimmer flights Stainless steel 304L or GRP
Skid rails Stainless steel
Conveyor chain Stainless steel, pp.
Power ½ hp

DAF Recycle
pump:
Brand Ebara , Lowara
Type End suction centrifugal pump
Capacity & pressure 4 m3 / hr. @ 2.5 bar.
Power 1kw
Origin Japan
Qty Two (1 duty/ 1 standby)

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Piping material PVC

Biological daf (high-rate sedimentation with lamella assets):

Diffusion Drum

Quantity One for settlement hopper

Dimensions 2.0 m * 0.8 m * 0.162 m (L*W*H)
Type Cylindrical
Material Stingless steel 304l

Scum box:
Quantity One for settlement hopper
Material Stainless steel 304
.

Lamella Sheets:
Quantity 8
Dimensions (1.3*0.3*0.3) m3
Material PVC

Overflow weirs:
Quantity One for settlement hopper
Type V- Notch gate
Material Stainless steel 304

biological daf scraper:

Quantity 5
Drive unit Geared motor
Provided with Slip rings

Air Blowers:
Qty. 2 (1duty/1standby)
Duty 750 m3/hr. @ 500 mbar
Power 20 kw
Accessories Steel support frame
Pressure gauge
Inlet filter silencer
Discharge silencer
Flexible connection
Anti-vibration beds
Material Cast iron (Casing, rotor & cover)
Chrome steel (shaft)
Origin Europe

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Fine Bubble Air Diffusers
Qty. 200
Type Fine bubbles air check diaphragm
Material Plastic body with rubber diaphragm

Filtration system

Filter Feed Pumps

Quantity Two (1 duty/ 1 standby)
Type Horizontal, End Suction Pump
Capacity 6.25m3/hr. @ 4.5 bar
Material Stainless Steel for shaft & impeller
Cast iron for casing
Power 2.3 kw
Brand Ebara, LOWARA
Origin Japan or Italy

Filter Backwash Pumps

Quantity Two (1 duty/ 1 standby)
Type Horizontal, End Suction Pump
Capacity 6.25 m3/hr. @ 2 bar
Material Stainless Steel for shaft & impeller
Cast iron for casing
Power 2.3 kw
Brand Ebara, LOWARA
Origin Japan or Italy

Multimedia Filters: (Sand & graduated gravel)

Quantity two (1 duty/ 1 standby)
Diameter 22 Inch
Height 72 Inch
Material Fiber glass
Operating pressure 3 to 6 bar
Max temp 45 °C
Provided with Pressure gauges for measuring pressure

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Sludge treatment
Q PRESS MACHINE (Capacity 0.5 m3/hr.)

Cost-effective sludge dewatering for independence in sludge disposal

The Q-PRESS is a screw press with a conical screw shaft and cylindrical sieves consisting of three treatment
zones: inlet and drive zone, three-part thickening and dewatering zone, and press zone with pneumatic
counter-pressure cone.

In the first part of the thickening and dewatering zone the supernatant is quickly removed by the feed
pump via a large free filter surface at a low primary pressure. A pressure probe in the feed area controls
the primary pressure thus ensuring a constantly high filtrate quality.

In the second part of the screen the volume of material between the screw flights is reduced by the conical
screw and the sludge pressed against the inner screen surface so that the sludge is dewatered, with a
continuous reduction of the filter cake thickness. The screen apertures are much smaller in this screen
section.

In the third part of the screen the residual water is pressed out of the sludge, at a minimum filter cake
thickness, by the pneumatic counter pressure cone at the press discharge. The dewatered sludge is pushed
by the conveying screw past the pressure cone into the discharge chamber. The sludge residence time in
the screw press and thus the filtration time can be adjusted to individual requirements by adjusting the
rotational speed of the screw shaft.

 Dewatering of thin sludge

Due to pump feeding, large volumes of sludge water are removed already in the pre-dewatering zone. This
permits cost-efficient dewatering of thin sludge with a solid’s concentration < 1%. This application allows
typical dewatering results of 18 – 25% DS and achieves a sludge volume reduction up to > 97% in a single
step!

 Variable sludge characteristics

Dewatering performance is usually impaired and operator attention increased by frequently varying sludge
quality. Our Screw Press Q-PRESS automatically self-adjusts to over- and under loading. A control loop
makes sure that optimal operation is always maintained.

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 Components:

* 304 SS Screw, Main Body

* Sludge thickening & dewatering zone

* Sludge flocculation tank

* Filtrate collection tank

* Automatic / automated control panel

* Fixed plates and moving plates instead of filter cloth

* System feed pump (diaphragm pump 2inch)

* System cleaning pump (Ebara 1.5 hp up to 6 bar)

Second stage of dewatering unit:

Moving the sludge from QPRESS to loading container

Screw moving conveyor

 Features

* UP to 4.5 m long with 6’’ diameter

* Stainless Steel 304 l moving conveyor

* Anti-acids l bearing system

* 2 hp Italy driving motor with gear box connected to variable-frequency drive (VFD) to control speed.

* Can stand alone or as a part of full mechanism

* Stainless steel 304 control panel with Schneider component

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Control Panel
Purpose: To provide a complete central motor control center, pre-wired & ready for installation

Quantity One
Free standing control panel completely assembled, wired
Type and tested at the factory. The panel shall be fabricated in
sheet steel, shaped and reinforced to form a rigid front
access enclosure.
The panel should be complete with all pushbuttons, fuses,
Mounting selector switches, contactors, relays, indicating lights,
timers etc. to form a local central control station
Wiring shall be brought out to screw type terminal block,
Cabling
labeled and identified in accordance with wiring diagram
All equipment and major devices shall be provided with
nameplates in English engraved plastic and all
Nameplates
pushbuttons and selector switches shall be appropriately
tagged.
All steel work shall be bonderised or given similar
Finish treatment before priming and painting with epoxy paint
to a smooth finish
Starters The panel shall accommodate starting contractors for all
motors. The starters shall be controlled through PLC.
Lights Alarms, indicator lights and other auxiliaries.
Main power supply 380 volt/ 3 phase/ 50 cycles

Plant Wiring
This shall be provided where scope incudes installation.
Cables shall be suitably sized for the appropriate duty, PVC sheathed and extended only between the local panel and
the individual drives and controls in the scope of this offer.

Pipework
The process and interconnecting pipework for the treatment plant will generally be in UPVC, as described under the
various sections of this specification. All UPVC pipework exposed to direct sun light shall be protected with suitable
alkyd-based paint.

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DRAWINGS

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 ‫المعادى الجديدة – القاهرة – جمهورية مصر العربية‬- 18 ‫ شقه‬- ‫ – الدؤر االول‬93 ‫عمارات امتداد االمل – عمارة‬
) + 020 ( 072270587 : ‫تليفاكس‬
EMTAD ELAAML -BORG 93 FIREST FOOR FL.NO.18 New Maadi Tel. Fax. (+202 ) 27007258
E mail adelmm50 @ gmail .com & adelmm40@ yahoo .com

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