introduction of project for upgrading industrial wastewater treatment and...
TRANSCRIPT
Introduction of project for upgrading industrial wastewater treatment and reducing CO2emissions in Indonesia by aerator
Jakarta, Indonesia, 27th September 2017
EMATEC (Environmental Management and Technology Center)MURC (Mitsubishi UFJ Research and Consulting)SUZUKI (Suzuki Industry)
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Introduction of team
Introduction of our teamEMATEC, MURC and SUZUKI have established consortium for promoting industrial wastewater treatment in Asian countries by “Aerator technology” in 2014.Now we are running 2 aerator projects in Indonesia supported and funded by MOEJ (Ministry of the Environment of Japan).
EMATECEMATEC (Environmental Management and Technology Center) is a foundation for environmental monitoring in Osaka which is established by Osaka prefectural government. EMATEC is a representative of the consortium and in charge of environmental monitoring.
MURC
In the team, position of MURC is
MURC (Mitsubishi UFJ Research & Consulting Co., Ltd.) is a consulting company in Tokyo and a major member of Mitsubishi UFJ Financial Group.In the team, position of MURC is a project coordinator and in charge of CO2 reduction.
SUZUKISUZUKI (Suzuki Industry Co., Ltd.) is an environmental research and manufacturing company in Kyoto.Role of SUZUKI is to analyze situation in each treatment facility and to provide detailed aerator installation plan. Also, aerator is provided by SUZUKI.
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Introduction of Aerator
What is aerator?Aerator is an aeration device for industrial and domestic wastewater treatment facility. Mainly aerator is installed at aeration tank and/or equalization tank. In Japan, more than 600 factories are using SUZUKI aerator.Compared with other conventional aeration devices (diffuser, surface aeration system, air mixer etc.), aerator has advantages in aeration capacity and electricity consumptionat blower.
Aerator
Dia. Len. Materials Weight Unit air capacity
Aeration area
125mm 680mm SUS, ABS 8kg 0.7-1.4 m3/min 6.0m3
Dimension of aerator
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Introduction of Aerator
Aerator installation
Installation of aerator
Aerator layout at aeration tank
Aeration by aerator
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Introduction of Aerator
Mechanism of aeratorAir from blower is mixed with wastewater at guide vane in the bottom of aerator and produce strong upward swirling flow. During swirling process, air is diffused to minute bubble at the inside wall of aerator.
Wastewater flow
Guide vane
Strong swirling flow with minute air bubble
Bottom
Air from blower
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Introduction of Aerator
Advantages of AeratorAerator generates strong air and wastewater circulation in tanks with less air pressure loss (almost zero loss) compared with conventional diffuser.This function contributes to reduce electricity consumption at blower and CO2 emissions.
Reduction of organic pollutants in wastewaterIncrease of wastewater treatment capacity30–50% Reduction of electricity consumption (electricity cost reduction and CO2 reduction)Maintenance free more than 10 yearsReduction of residual sludgeLess odor from aeration tankEasy installation
Reduction of organic pollutants in wastewaterIncrease of wastewater treatment capacity30–50% Reduction of electricity consumption (electricity cost reduction and CO2 reduction)Maintenance free more than 10 yearsReduction of residual sludgeLess odor from aeration tankEasy installation
<Advantages of Aerator>
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Example of aerator installation
Project outlineAerator installation project (private company project) for industrial wastewater treatment facility at industrial estate in Thailand.Project duration: January 2017 – May 2017
Item Condition
Type of wastewater Mixed wastewater from industrial estate
BOD concentration <500mg/LDO concentration 0.5mg/LWastewater amount 18,000 m3/dayAeration device Diffuser
Condition before project
Previously used diffuser
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Example of aerator installation
Aerator installation layoutNumber of aeratorTank1: 80 unitsTank2: 90 units
Number of blowerBefore: 11kW x 10 unitsAfter: 55kW x 1 unit
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ResultDO has been improved by 280% in tank1 and by 130% in tank2.Average DO in tank1 increased from 0.5 mg/L to 1.9 mg/L. Average DO in tank 2 increased from 0.9 mg/L to 2.1 mg/L.
Before
After
After
Before
Tank1
Tank2
Example of aerator installation (DO)
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Item Unit Before After Difference
Air flow from blower m3/min 54 40 ---Number of blower Unit 10 1 ---Blower capacity kW 11 55 ---Electricity consumption kWh/year 963,600 430,291 -533,309Electricity Unit Price Baht/kWh 3.3Electricity cost Baht/year 3,179,880 1,419,960 -1,759,920
ResultAs aerator needs less air pressure than diffuser, existing old blowers (11kW x 11units) were replaced by a new blower (55kW x 1unit).As a result of blower replacement, electricity consumption was decreased by 55%. Yearly electricity reduction is estimated as 533 MWh/year and amounts 1,760,000 Baht (around 53,000 USD).Yearly CO2 reduction will be around 320 tCO2/year.
Example of aerator installation (Electricity)
Electricity consumption before and after project
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Introduction of current projects in Indonesia
For leather industry (2016-18)This project focuses on how to increase capacity of organic wastewater treatment at a wastewater treatment facility in leather industrial estate.
For rubber industry (2015-17)This project focuses on electricity reduction of blower for aeration tank in rubber industry without negative impact to aerobic treatment at their wastewater treatment.
Since air pressure loss at aerator (80mmAq) is much smaller than diffuser (1,000mmAq), necessary electricity power for blower running can be reduced.
Since aerator enables intermittent air supply from blower (diffuser needs continuous air supply), blower operation can be controlled intermittently and electricity consumption can be reduced.
Pressure loss reduction Intermittent air supply
Since aeration capacity of aerator is stronger than diffuser, retention time at aeration tank can be shortened and amount of wastewater can be increased.
Shorter retention time
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Project at leather industry
backgroundThe target facility collects wastewater from around 100 leather processing factories and treats industrial wastewater by diffuser. Now, wastewater production from factories are increasing and reaching almost maximum capacity of the facility because of increase of leather products.Therefore, the Team proposed to substitute existing diffuser by aerator and increase wastewater capacity without expanding aeration tank because there is no space for new tanks.
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Project at leather industry
Characteristics of wastewaterFluctuation of pH and flowrateIncreasing amount of wastewaterHazardous chemicals such as Cr and high concentration of organic matter (COD 1,000 – 2,000mg/L) and NaClLocated in the central city, surrounded by residential areaNo additional lands for installing new tanksDecrease of river water in dry season
Sources of wastewater
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Project at leather industry
SolutionReplacing diffuser with aerator at aeration tanks for better activated sludge process and reducing sludgeEnhancing mixing capacity at equalization tank and improving sedimentation processConsultation for reducing wastewater and chemicals at each factory and introducing recycled wastewater for some processes
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Project at rubber industry
Previous conditionBefore the project, this company (natural rubber company) treated industrial wastewater from rubber producing processes by aeration system with conventional diffuser for meeting provincial wastewater quality standards.
WWTP1 (4,725m3/day) WWTP2 (9,165m3/day)
WWTP: WasteWater Treatment Pond
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Target of the projectThis project aims to enhance wastewater treatment capacity as well as to reduce electricity consumption and cost for renewal of diffuser by replacing existing diffuser with aerator.
Existing diffuser(WWTP1: 856units, WWTP2: 1,680units)
Electricity reduction at blower
Aerator(WWTP1: 214units, WWTP2: 288units)
7 blowers in total
Project at rubber industry
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ProgressAll aerators and other equipment have been installed successfully until July 2017.
Next stepDuring August – October 2017, trial intermittent blower running will start operation considering outlet wastewater quality.Electricity reduction at blower will be monitored after blower running schedule will be decided.
Inflow tankUltrasonic flow meterAerator installationAir flow piping
Project at rubber industry
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Monitoring itemsElectricity consumption at blower will be monitored continuously by electricity meter.Electricity consumption in reference scenario will be estimated by using pressure data (before and after aerator installation) and performance data table of blower made by blower manufacturer.If BOD (or COD) data exceeds wastewater quality standards accidentally, submission of JCM credit will be stopped until wastewater quality will be recovered.
Data monitoring equipment
Project at rubber industry
