To : PT Southern Chemicals & Engg

Preliminary Study
of
Wastewater Treatment System
with Kubota Submerged Membrane Units
for
Green Bay STP, Indonesia

22 November, 2011

KUBOTA Corporation
Kubota is a leading company in environmental fields. In the field of wastewater treatment, we work as
an engineering company for construction of sewage treatment works, night soil treatment plants and
the other wastewater treatment plants in Japan. Especially as for the membrane technology, we were
an user for various kind of membrane modules and more than twenty years ago, we started to develop
our membrane unit exclusively for wastewater treatment as there was no reliable membrane module in
the market at that time. The result is our flat sheet membrane. After we developed the units, we
started to work as s supplier of our membrane unit worldwide. The number of references reaches more
than 3,800 plants in the world.

The membrane plant of the Kubota system is very simple with easy maintenance. The Kubota
membrane system is applied to various applications which include sewage, industrial wastewater such
as wastewater from brewery, dairy, food processing and pharmaceutical production, etc, recycled water
usage, sludge liquor treatment.

Item 1, 2 and 3 in this study show outline of our membrane units proposed for this project. Items after
Item 4 show the outline of the system for your project.

1 Description of unit

The ES type submerged membrane unit (SMU) is divided in the two sections; i.e. the membrane case in
which membrane cartridges are installed and the diffuser case which supports the membrane case and
equips with a diffuser pipe. The function of this diffuser case is to confine air in the membrane unit so
as to facilitate sweeping flow in the up-ward direction. The air is supplied through a pipe diffuser with
holes of a coarse size, which is located near the bottom of and inside the diffuser case.

Each of the membrane cartridges (panels) is connected through a permeate tube to a permeate
collection manifold. The driving force to collect permeate can be got either by the gravity force or by a
suction pump.

EK type of unit is the double deck unit which consists of two membrane cases stacked on the diffuser
case.

Fig 1 shows the structure of ES type membrane unit. Photo 1 shows EK type (double deck type of unit)
which has two membrane cases.

Tube

Membrane Case

Manifold
Membrane Cartridge

Diffuser Case

Diffuser

Photo 1 EK type membrane unit

Fig. 1 ES type membrane unit
2 Structure of membrane cartridge

Membrane sheets are ultrasonic-welded Nozzle Supporting plate

on both surfaces of a supporting panel.
Membranes are made from chlorinated Spacer
polyethylene with nominal pore size of 0.4
um (average : 0.2um). Spacers are also Membrane sheet
provided between a membrane sheet and
the supporting panel on both sides.
Treated water permeates through the
membrane sheets and the spacers to Microstructure
come out via nozzle, tubes.

Fig. 2 Structure of Membrane

cartridge

3 Description of ES150 unit

Type of membrane unit: ES150

Number of cartridge:
Filtration area per cartridge:
Filtration area per unit:
Pore size
150 cartridges per unit
2
0.8 m per cartridge
2
120 m per unit
Nominal diameter 0.4 um

Air volume
Air volume per membrane cartridge: 10 l/min/cartridge (max. 15 l/min/cartridge)
3 3
Air volume per membrane unit 1.5 m /min/unit (max. 2.25 m /unit)

Dimension 600 mm x 2,200 mm x 2,030 mmH

Dimension for main body except permeate tubes, manifold, etc.
Weight of unit
Membrane case: 550 kg
Diffuser case: 80 kg
Required lifting capacity: 1,200 kg (Lifting tool is included, but weight of chains is excluded.)

Chemical cleaning in situ

Kind of chemical
Sodium hypochlorite effective chlorine concentration 0.5% for organic fouling
Oxalic acid concentration 1.0% for inorganic fouling
Volume: 3 litre/cartridge with above mentioned concentration
450 litre/each upper or lower membrane case plus volume in pipe
Chemical solution pouring pressure: 10 kPa or less as constant pressure

Filtration method
Suction filtration with pump
Filtration pressure: max. 20 kPa
Filtration mode: Intermittent filtration with 9 min on/1 min off
4 Design Conditions
Description Unit Influent Treated water Remarks
3
Average flowrate m /d 550 -
3
Max. daily flowrate m /d Not specified - Note 1
3
Hourly flowrate m /h Not specified -
BOD5 mg/l < 350 <5 Note 2
CODcr mg/l Not specified Not specified
TSS mg/l Not specified Not specified
T-N mg/l < 50 Not specified Note 2
NH3-N mg/l < 50 < 10 Note 2
T-P mg/l Not specified Not specified
FOG mg/l Not specified Not specified Note 3
E Coli Not specified Not specified
pH Not specified Not specified
Water temperature C deg. 20 at lowest -
3
Note 1: If max. daily flowrate is higher than 550 m /d, then the design will be restudied.
2: Influent quality is just estimated by Kubota.
3: If FOG is more than 15% BOD, it's necessary to decrease FOG by pre-treatment.

5 Process flow
Wastewater

Coarse screen

Equalization tank

Fine screen

MLSS: 8,000 mg/l

Pre-aeration tank Return activated
sludge (2Q)

MBR tank MLSS: 12,000 mg/l

Excess sludge

Treat water tank Sludge storage tank

6 Schematics for Process with Kubota Submerged Membrane Unit

Clean water

P
Chemical tank
Mixing

B B B
Treated
PI FI water tank
*1 P
M *1

Fine
screen

P P

EQ tank Pre-aeration tank MBR tank RAS tank

7 Tank volume and Oxygen requirement
7.1 Calculation of tank volume
7.1.1 Tank volume of main tanks
Name of main tank Required volume Actual volume & tank size
3
Equalization tank (Note 4) m x x mH 0 m3 x 0 m
3

Pre-aeration tank 103.7 m3 5.0 x 7.3 x 3.0 mH 109.5 m3 x 1 109.5 m3

3
MBR tank 91.3 m 4.5 x 3.5 x 2.9 mH 45.6 m3 x 2 91.3 m3
Note 4: Equalization tank volume shall be studied according to the peak flow pattern, etc.

7.1.2 Calculation
1) Membrane unit
3
a) Design flowrate (Average flow) 550 m /d
2
b) Membrane effective surface area 0.8 m /cartridge
c) Design flux 0.60 m3/m2/d
d) Nos. of membrane cartridge 1,146 pcs
e) Type of Submerged membrane unit ES150
f) Nos. of membrane cartridge per unit 150 pcs/unit
g) Nos. of membrane unit 8 units
h) Total number of cartridges 1,200 pcs

2) MBR tank volume

a) Tank size Length 4.5 m
Width 3.5 m
Depth 2.9 m
Nos. 2 Tanks
b) MBR tank volume per tank 45.7 m3
3
c) MBR tank volume 91.3 m
d) MLSS in MBR tank 12,000 mg/l

3) BOD removal in MBR tank

3
a) Design flowrate (Average flow) 550 m /d
b) Influent BOD 350 mg/l
c) BOD load 193 kg-BOD/d
d) BOD removal rate 0.10 kg-BOD/kg-SS/d (20 degrees C)
e) BOD removal rate per unit volume 1.2 kg-BOD/m3
f) BOD removal in MBR tank 109.6 kg-BOD/d

4) Nitrification in MBR tank

a) T-N load for nitrification 27.5 kg-N/d
b) Nitrification rate 0.025 kg-N/kg-ss/d (20 degrees C)
c) MLSS in MBR tank 12,000 mg/l
d) Nitrification rate per unit volume 0.30 3
kg-N/m
e) Nitrification in MBR tank 27 kg-N/d
5) Pre-aeration tank volume
a) Required BOD Removal in Pre- aeration tank 82.9 kg-BOD/d
b) BOD removal rate 0.10 kg-BOD/kg-SS/d (20 degrees C)
c) MLSS in Pre-aeration tank 8,000 mg/l
d) BOD removal rate per unit volume 0.80 3
kg-BOD/m
3
e) Required Pre-aeration tank volume for BOD 103.7 m
f) Required Nitrification in Pre- aeration tank 0.1 kg-N/d
g) Nitrification rate 0.025 kg-N/kg-ss/d (20 degrees C)
h) MLSS in Pre-aeration tank 8,000 mg/l
i) Nitrification rate per unit volume 0.20 3
kg-N/m
3
j) Required Pre-aeration tank volume 0.6 m
k) Tank size Length 5.0 m
Width 7.3 m
Depth 3.0 m
Nos. 1 Tank
l) Pre-aeration Tank volume per tank 109.5 m3
3
m) Pr-aeration tank volume 109.5 m
7.2 Oxygen requirement and actual air volume
7.2.1 Oxygen requirement for biological treatment
Required oxygen for BOD removal 96.3 kg-O2/d
Required oxygen for Nitrification 125.7 kg-O2/d
Required oxygen for endogenous respiration 201.2 kg-O2/d
Total required oxygen 423.1 kg-O2/d

7.2.2 Oxygen value in tanks

Name of tank Oxygen volume Remarks
Pre-aeration tank 269.9 kg-O2/d This oxygen should be supplied by fine
bubble diffusers.
MBR tank 153.2 kg-O2/d This oxygen is supplied by diffusers of
membrane units.

7.2.3 Actual aeration volume

Fine bubble diffuser 15,227 m3/d 10.6 m3/min. Note 5
Membrane unit 17,280 m3/d 12 m3/min.
Note 5: Diffusers with 10% oxygen transfer efficiency and 0.8 alpha factor are used in this calculation.

7.2.4 Calculation
1) Required oxygen for BOD removal
a) Design flowrate (Average flow) 550 m3/d
b) Influent BOD 350 mg/l
c) Required unit oxygen for BOD removal 0.5 kg-O2/kg-BOD
d) Required oxygen for BOD removal 96.25 kg-O2/d

2) Required oxygen for nitrification

a) Required oxygen volume for nitrification 64/14
b) T-N load for nitrification 27.5 kg-N/d
c) Required oxygen for nitrification 125.7 kg-O2/d

3) Required oxygen for endogenous respiration

3
a) MBR tank volume 91.3 m
b) MLSS in MBR tank 12000 mg/l
3
c) Pre-aeration tank volume 109.5 m
d) MLSS in pre-aeration tank 8,000 mg/l
e) Required oxygen for endogenous respiration 0.12 g-O2/g-VSS
f) MLVSS/MLSS ratio 0.85
g) Required oxygen for endogenous respiration 201.2 kg-O2/d

4) Total required oxygen for biological treatment 423.1 kg-O2/d

5) Oxygen supplied by membrane unit

a) Air volume of one membrane cartridge 10 l/min/cartridge
b) Number of membrane cartridge per unit 150 pcs/unit
c) Number of unit 8 unit
d) Total air volume for membrane 12 m3-air/min
3
e) Oxygen content per 1 m3 of air 0.277 kg-O2/m
f) Oxygen transfer efficiency of clean water 5 % at 2.9m water level
g) Alpha factor 0.8 at 1.2% MLSS
h) Safety factor 0.8
i) Oxygen supplied by membrane unit 153.2 kg-O2/d

6) Required oxygen supplied from fine bubble diffuser 269.9 kg-O2/d

8 Size for MBR tank
Membrane unit ES150

900
4,500
More than
3,500
2,000

3,500 3,500

MBR tank layout plan SECTION

9 Layout
Inlet

Pre-aeration tank 5,000

(Water Level 3.0m)

MBR tank
(Water Level 2.9m) 4,500

P RAS tank

3,500 3,500

7,300
 10 Specification of major equipment

No Mark Description Q'ty Specification for one equipment

1 Fine screen 1+1 Bar type w/scraper, 23 m3/hr or more, Opening 1.0mm
3
2 B Blower for fine bubble diffuser 1+1 10.6 m /min or more at pressure of 40kpa
3 Fine bubble diffuser Total oxygen supply 270 kg-O2/d
4 B Blower for membrane unit 2+1 6.0 m3/min at pressure of 40kpa
5 P Permeate pump 2+1 3
Self-priming centrifugal pump, 0.22m /min or more at
head of 10 m
3
Recirculation pump More than 0.77 m /min x 4mH
6 P (RAS to Pre-aeration tank) 1+1
7 Membrane unit 8 Flat sheet membrane Kubota ES150
8 PI Pressure gauge 2 Measuring range: -100kPa to +100kPa
9 FI Magnetic flow meter 2 0.3 m3/min