DESIGN AND APPLICATION OF WASTEWATER TREATMENT … · Pempek is one of Indonesia’s popular traditional foods, originated from Palembang City, Sumatra, Indonesia. Tasteful pempek

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International Journal of Civil Engineering and Technology (IJCIET) Volume 9, Issue 13, December 2018, pp. 1751-1765, Article ID: IJCIET_09_13_174

Available online at http://www.iaeme.com/ijciet/issues.asp?JType=IJCIET&VType=9&IType=13

ISSN Print: 0976-6308 and ISSN Online: 0976-6316

© IAEME Publication Scopus Indexed

DESIGN AND APPLICATION OF

WASTEWATER TREATMENT PLANT FOR

“PEMPEK” FOOD INDUSTRY, SURABAYA,

INDONESIA

Ipung Fitri Purwanti

Department of Environmental Engineering, Faculty of Civil, Environmental and Geo

Engineering, Institut Teknologi Sepuluh Nopember, Jalan Raya ITS, Kampus ITS Sukolilo,

Surabaya 60111, Indonesia

Harmin Sulistiyaning Titah




Bieby Voijant Tangahu




Setyo Budi Kurniawan




ABSTRACT

Pempek is one of Indonesia’s popular traditional foods, originated from Palembang

City, Sumatra, Indonesia. Tasteful pempek obtained from mackerel fish processing. As

by-product of pempek processing, wastewater contain high concentration of organic

and nitrogen was released to environment. COD content was measured up to

11,760mg/L, followed by BOD up to 7,996 mg/L and N total measured as NH3-N

reached 454.03 mg/L. The effluent standard for fish processing wastewater sets by East

Java Government were 150 mg/L for COD, 100 mg/L for BOD and 5 mg/L for NH3-N.

A challenge to make cheap and easy-to-operate technology lead to a combination of

biological and phyto-treatment processes that designed and applied for this wastewater

to meet the East Java Government’s effluent standard. The wastewater treatment plant

(WWTP) used in this research consisted of control box, grease trap, sedimentation tank,

Ipung Fitri Purwanti, Harmin Sulistiyaning Titah, Bieby Voijant Tangahu and Setyo Budi

Kurniawan


anaerobic baffled reactor (ABR), anaerobic bio filter (ABF) and constructed wetland

(CW). This WWTP could reduce up to 99.71% of COD, 99.76% of BOD, 98.9% of

nitrogen content, 99.75% of oil and grease in wastewater.

Key words: High Organic, Mackerel Fish, Nutrient, Traditional Food, WWTP

Cite this Article: Ipung Fitri Purwanti, Harmin Sulistiyaning Titah, Bieby Voijant

Tangahu and Setyo Budi Kurniawan, Design and Application of Wastewater Treatment

Plant for “Pempek” Food Industry, Surabaya, Indonesia, International Journal of Civil

Engineering and Technology, 9(13), 2018, pp. 1751-1765

http://www.iaeme.com/IJCIET/issues.asp?JType=IJCIET&VType=9&IType=13

1. INTRODUCTION

Pempek is one of Indonesian traditional culinary which come from the city of Palembang,

South Sumatra, Indonesia [1]. It is very tasteful and contains high protein. Delicious pempek

comes from the processing of mackerel fish. Mackerel fish pass through several processes such

as washing, filleting, boiling until frying before it can be served [2]. From this stage of the

process, liquid waste containing high organic matter, nutrients, oils and fats generated [3].

Due to the high demand, some pempek home-scale manufacturing industries are emerging.

One of home-scale pempek industries is in Rungkut District, Surabaya City, Indonesia. At

average, 150 kgs of fresh mackerel fish are processed into delicious pempek every week [4].

Unfortunately, wastewater that generated from the process was not properly treated. This

wastewater had a cloudy color and smelled unpleasant. If directly disposed into the

environment, this waste can cause environmental pollution that can disrupt the surrounding

environment including human life [5].

Generally, pempek wastewater contains high organic matter, high Total Suspended Solid

(TSS), and high nutrient [6]. Previous research showed that pempek wastewater has Chemical

Oxygen Demand ranged 5,000 from to 20,000 mg/L, BOD content from 5,000 to 15,000 mg/L,

and Nitrogen content around 0-25 mg/L. These values were highly exceeding the quality

standard set by East Java Government for fish processing industry which were 150 mg/L for

COD, 100 mg/L for BOD and 5 mg/L for NH3-N [7]. Wastewater treatment need to be carried

out to meet the East Java Government’s quality standard.

A challenge to make a cheap and easy-to-operate technology that require minimum

maintenance was our main goal to be achieved. A combination of physical and biological

treatment usually used to treat wastewater containing high organic matter, high TSS and high

nutrient [8, 9, 10] and require minimum technical maintenance. Grease trap is widely known

as a unit to remove oil and grease content in wastewater [11]. Sedimentation tank can be used

to reduce high content of TSS before entering the biological process [12, 13]. Anaerobic

biological process can reduce high concentration of organic matter [14] and phyto-treatment is

widely used to remove high nutrient content in wastewater [15]. So far, research on pempek

wastewater is only conducted on laboratory scale, study about the design of pempek wastewater

treatment process in real scale has not been widely discussed. It is also considered interesting

because pempek is a unique food product from Indonesia. For that reason, this research was

aimed for designing and applying wastewater treatment plant for pempek industry to meet the

effluent quality standards for fish processing industry. The result of presented research may

highlight the efficiency of using combined biological processes in treating wastewater

containing high organic concentration.

Design and Application of Wastewater Treatment Plant for “Pempek” Food Industry,

Surabaya, Indonesia


2. MATERIALS AND METHOD

2.1. Location Survey

Location survey was conducted to determine the possibility of treatment units to be built.

Survey was also conducted to determine the location for units to be built inside the area [16].

Survey was conducted by direct visit to Pempek Tjek Entis business location. It also aims to

map the location to organize the placement of the unit [16]. All units for this wastewater

treatment plant were designed according to the free space for placement that obtained from

location survey.

2.2. Wastewater Characterization

Wastewater characterization was carried out by analyzing pH, Total Suspended Solid (TSS),

Chemical Oxygen Demand (COD), Biological Oxygen Demand (BOD), and N ammonia as

NH3-N. Wastewater that used for characterization was taken from the effluent of water

discharge facility inside the industry. pH was analyzed by pH meter (pHonLab, Germany), TSS

was analyzed by using gravimetric method [17], COD was analyzed by Close Reflux Method

[18], BOD was analyzed by Winkler titration [19], and NH3-N determined by Kjeldahl method

[20]. Initial wastewater characterization then compared with East Java Government Regulation

about Fish Processing Wastewater Standard No 72, 2013 [7].

2.3 Wastewater Treatment Plant (WWTP) Design

Design of each unit was conducted according to the result of initial wastewater

characterization. Unit design included a calculation of dimensions tailored to the availability

of land space. Pempek wastewater contain high amount of oil and grease, high concentration

of suspended solid, high concentration of organic matter, and nitrogen. A combination of

physical and biological treatment was used to treat the wastewater. Based on its characteristic,

WWTP consisted of control box, grease trap, sedimentation tank, anaerobic baffled reactor

(ABR), anaerobic bio filter (ABF) and constructed wetland (CW) is chosen.

The grease trap dimension calculations were carried out referring to Orange County

Sanitation District [21]. Manual cleaning was designed for grease trap and 100% of oil and

grease removal was expected from this design. The effluent from this unit was planned to enter

the sedimentation tank. Sedimentation tanks were designed referring to Swamee and Tyagi

[22]. Three circular sedimentation tanks were made by using connecting vessel system. This

design was chosen because of the limitation of land space. Sedimentation tanks were designed

to remove up to 66% of TSS and 27% of organic matter in wastewater.

After going through the sedimentation tank, wastewater will be processed in ABR unit and

followed by ABF unit. The design of ABR and ABF were carried out referring to BORDA [23]

and Chernicharo [24]. ABR and ABF were calculated to have 85% of BOD removal efficiency.

After passing through ABF, the effluent was going to CW as the last treatment unit. CW was

designed according to USEPA [25]. All hydraulics flow was designed by gravity, although

pumping was still needed to bring water from ABF to CW.

2.4 WWTP Application and Pollutant Removal

WWTP installation was performed by building all designed unit using concrete construction.

After all unit were built, a leakage check was performed for all unit to prevent wastewater

permeation. Re-water proofing was performed for all units indicated to leak. After all

construction works were complete, one liter of bacterial seed (EM16, Indonesia) was poured

into ABR and ABF. CW then planted with Scirpus grossus and Thypa angustifolia referring to


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Jinadasa et al. [26] and Purwanti et al. [27]. The effluent of WWTP was tested after 2 weeks

running of wastewater flow to achieve the steady state condition [28]. Effluent check was

performed by taking 500 mL of wastewater in the outlet of CW. The outlet of CW was

connected to tertiary urban drainage channel, so the sample taken was indicating the result of

WWTP that will be discharged to environment. WWTP removal was checked by taking sample

from the effluent of CW as the last treatment unit after the steady state. Parameter tested consist

of TSS, COD, BOD, NH3-N, oil and grease. The result of parameter tested then compared to

initial wastewater characteristic before treatment [29]. All parameter tested for treated

wastewater were also compared to the effluent standard to check whether the effluent was

already meet the quality standard or not.

3. RESULT AND DISCUSSION

3.1. Location Survey

Location survey results showed that the industry has a narrow location for the placement of

wastewater treatment units. The free space consists of two parts with a total area of 16.5m3.

Location 1 was elongated shape with a length of 9m and width of 1m. Location 2 was

rectangular shape with 3m in length and 2m in width. These two locations were showed in

Figure 1.

3.2. Wastewater Characteristic

Wastewater had a continuous flow for every day with 1m3 of average flow rate per day. A peak

day was occurred once a week in fish filleting process. A peak flow rate was calculated as 2m3

per day during filleting process. The peak flow rate was chosen as design flow rate to

accommodate all wastewater to be treated further [30]. Wastewater was discharged through

pipe and later would be connected to control box of WWTP. Wastewater characterization was

carried out by taking sample from discharge pipe. Result of parameter analysis showed on

Table 1.

Table 1 indicating that all parameter tested for pempek wastewater did not meet the quality

standard. All parameters tested except pH highly exceed the quality standard especially for

BOD, COD and Nitrogen. The pH tested was below the quality standard which was tending to

be acidic. Based on the result, pempek wastewater classified as high organic and nutrient

wastewater [10]. To meet the quality standard, a combination of physical and biological process

was chosen as treatment for wastewater [28]. Grease trap was chosen to remove oil and grease,

sedimentation tank was chosen to reduce TSS content, Anaerobic Baffled Reactor (ABR) and

Anaerobic Bio-Filter (ABF) were chosen to reduce organic content and Constructed Wetland

(CW) was chosen to reduce Nitrogen content.


Surabaya, Indonesia


Figure 1 Free space in industry for WWTP

Table 1 Initial wastewater characteristic

Parameter Unit Result Effluent Standard Method

pH - 4.17 6-9 pHmeter

TSS mg/L 590 30 Gravimetric

BOD mg/L O2 7,996 100 Winkler

COD mg/L O2 11,760 150 Reflux

NH3-N mg/L 454.03 5 Kjeldahl

Oil and Grease mg/L 794 15 Gravimetric

3.3. Grease Trap Design

Grease trap was designed for a manual clean up. It consisted of 4 chambers and a coarse filter

was placed in the first chamber to separate bulk impurities. The other chamber was designed

using up-flow wastewater stream to trap oil and grease in the surface of water to be cleaned

further. This unit was designed to be cleaned up manually once a week, this schedule can be

adjusted according to the amount of bulk impurities, oil and grease that enter the WWTP.

Technical drawing of grease trap can be seen on Figure 2 and removal calculation showed on

Table 2.


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Figure 2 Grease trap

Table 2 Design calculation and removal of grease trap

Flowrate (Q) = 2 m3/day

= 23.14815 cm3/s

Length (l) = 80 cm

Width (w) = 40 cm

Surface Area (As) [l x w] = 3200 cm2

Depth (h) = 100 cm

Freeboard (fb) = 20 cm

Water Depth (hw) = 80 cm

Wet Volume (WV) [As x hw] = 256000 cm3

Time Detention (td) [WV / Q] = 11059.2 s

= 3.072 hour(s)

Oil and Grease [IN] = 794 mg/L

Oil and Grease Removal = 99 % [21]

Oil and Grease [OUT] = 7.94 mg/L

3.4. Sedimentation Tank Design

Sedimentation tanks were designed using cylinder packed concrete construction. This option

was chosen to accommodate the narrow area of free space. This option also chosen to utilize


Surabaya, Indonesia


the remains of unused buildings on site. 3-cylinder packed concrete constructions were placed

and connected by pipe. Each cylinder was 0.6m in diameter and 1m in high. 3 sedimentation

tanks that connected each other were designed to accommodate 2m3 of peak wastewater.

Sludge from sedimentation tank was designed to be drained once a year according to the

removal of TSS. Technical drawing of sedimentation tank showed on Figure 3 and removal

calculation showed on Table 3.

Figure 3 Sedimentation tank

Table 3 Design calculation and removal of sedimentation tank


= 23.15 cm3/s

Diameter (d) = 60 cm

Surface Area (As) [∏ x (d/2)2] = 2826 cm2

Depth (h) = 100 cm

Freeboard (fb) = 20 cm

Water Depth (hw) = 80 cm

Number of Sedimentation Tank = 3

Wet Volume (WV) [As x hw x 3] = 678240 cm3

Time Detention (td) [WV / Q] = 29299.97 s

= 8.14 hour(s)

COD [IN] = 14000 mg/L

COD Removal = 27 % [22]

COD [OUT] = 10220 mg/L

TSS [IN] = 531 mg/L

TSS Removal = 66 % [22]

TSS [OUT] = 182.133 mg/L


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3.5. Anaerobic Baffled Reactor Design (ABR)

ABR was designed according to the organic content in wastewater. ABR consisted of 4

chambers: 1 Sedimentation chamber and 3 baffled chambers. The first chamber was used to

accommodate TSS content and to precipitate BOD content into biomass sludge [23]. Sludge in

the first chamber was designed to be drained once a year. Technical drawing of ABR showed

on Figure 4 and removal calculation can be seen on Table 4.

Figure 4 Anaerobic Baffled Reactor

Table 4 Design calculation and removal of Anaerobic Baffled Reactor

ABR STABILIZATION TANK


= 23.15 cm3/s

Designed Time Detention (td) = 2 day(s)

Total Volume (V) [Q x td] = 4 m3

l:w:hw = 3:1:2

Water Depth (hw) = 1.5 m


Surabaya, Indonesia


Length (l) = 3.3 m

Width (w) = 0.8 m

Surface Area (As) [l x w] = 2.67 m2

Freeboard (fb) = 0.2 m

Depth (h) = 1.7 m

ABR COMPARTMENTS

Organic Loading Rate (OLR) = 3 Kg COD/m3.day

OLR Based Volume (V OLR) = 4.76 m3

Length (l) = 0.8 m

Width (w) = 0.8 m


Depth (h) = 1.7 m

Surface Area per Compartment [l x w] = 0.64 m2

Compartment Volume (V Comp) [l x w x hw] = 0.90 m3

Number of Compartment [V OLR / V Comp] = 5

COD [IN] = 10220.00 mg/L

COD Removal = 70 %

COD [OUT] = 3066 mg/L

TSS [IN] = 182.113 mg/L

TSS Removal = 50 %

TSS [OUT] = 91.06 mg/L

3.6. Anaerobic Bio Filter Design (ABF)

ABF was planned to reduce the remaining organic matter from previous unit. ABF was chosen

due to the calculated amount of organic content that still high after ABR treatment [23]. The

effluent of ABF was expected to have COD content under 1000 mg/L to prevent the death of

plant used in Constructed Wetland (CW) [24]. ABF consisted of 3 chambers: 2 filtration

chambers and 1 effluent collector chamber. Filtration chambers in ABF were filled by gravel

and sand as the filter medium for bacterial growth, this option was chosen because of the

abundant availability of this medium at the location. The collector chamber was designed to

collect the effluent from ABF to be pumped into CW. Technical drawing of ABF can be seen

in Figure 5 and removal calculation showed on Table 5.


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Figure 5 Anaerobic Bio Filter

Table 5 Design calculation and removal of Anaerobic Bio Filter


= 23.15 cm3/s

Volume of ABF (V) = 3.5 m3

Time Detention (td) [V / Q] = 1.75 day(s)

Water Depth (hw) = 1 m

Length (l) = 2 m

Width (w) = 1.5 m

Surface Area (As) [l x w] = 3 m2


Depth (h) = 1.2 m

COD [IN] = 3066.00 mg/L

COD Removal = 70 %

COD [OUT] = 919.8 mg/L

TSS [IN] = 91.06 mg/L

TSS Removal = 70 %



Surabaya, Indonesia


3.7. Constructed Wetland Design (CW)

CW was used to reduce high nutrient content in wastewater [15]. CW was planned as the last

treatment unit because the limitation of organic content that can be exposed to plant [24]. CW

was planted with Scirpus grossus and Thypa angustifolia [26, 27]. These plant species were

known to have high ability in resisting organic matter and high capability in removing nutrient

content [31, 32, 33]. CW was filled with soil medium and designed to have a sub-surface flow

[33]. Number of S. grossus and T. angustifolia was 1 for every 5 kilograms of medium used

[25]. Total medium used were 100 kilograms, so the number of S. grossus is equal to T.

angustifolia which were 10 plants. The effluent of CW was planned to be directly discharged

to tertiary drainage channel. Technical drawing of CW showed on Figure 6 and calculation of

parameter removal can be seen on Table 6.

Figure 6 Constructed Wetland

3.8. WWTP Start-up

After completely built all unit designed for WWTP, a waterproofing for all unit was conducted

to prevent wastewater leakage to the groundwater. A complete leakage check was carried out

by filling up all unit with tap water and let it over for 1 day, the surface of water level was

marked in every unit for further checking. Surface water level after 1 day of water filling then

checked. If the level is lower than the day marked before, those units would be drained, and re-

waterproofing will be carried out once again [34]. This stage was conducted until all unit were

confirmed to not to be leaked.


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Table 6 Design calculation and removal of Constructed Wetland


= 23.15 cm3/s

Volume of CW (V) = 0.75 m3

Time Detention (td) [V / Q] = 0.375 day(s)


Length (l) = 3 m

Width (w) = 0.5 m

Surface Area (As) [l x w] = 2 m2


Depth (h) = 0.6 m

Number of Plant = 10

COD [IN] = 919.80 mg/L

COD Removal = 90 %

COD [OUT] = 91.98 mg/L

TSS [IN] = 27.32 mg/L

TSS Removal = 70 %


NH3 [IN] = 454.03 mg/L

NH3 Removal = 90 %

NH3 [OUT] = 45.403 mg/L

WTP start-up was begun by inoculating sedimentation chamber of ABR and first filtration

chamber of ABF with one liter of bacterial inoculum solution (EM16, Indonesia) each. EM16

was used as bacterial seed to degrade organic content in wastewater [23]. After inoculation, an

acclimatization of all unit was carried out by filling and flooding all unit with real wastewater

[34]. Acclimatization was conducted to start the bacterial processes inside all unit until it met

the steady state. Acclimatization was carried out for 3 weeks [34]. After acclimatization stage,

the entire removal process in WWTP can be declared as stable. Complete unit series of WWTP

along with its hydraulic profile showed on Figure 7.

Figure 7 Profile of WWTP

3.9. WWTP Removal

Table 7 showed that all parameter tested were highly decreased compared to initial wastewater

characteristic. This result prove that high organic and nutrient wastewater can be treated using


Surabaya, Indonesia


a combination of physical, biological and phyto-treatment. Complete removal efficiency for

each parameter were shown on Figure 8.

Table 7 Treated wastewater characteristic

Parameter Unit

Initial

Wastewater

Characteristic

Treated

Wastewater

Characteristic

Effluent Standard Method

pH - 4.17 7.55 6-9 pHmeter

TSS mg/L 590 16 30 Gravimetric

BOD mg/L O2 7,996 19 100 Winkler

COD mg/L O2 11,760 34 150 Reflux

NH3-N mg/L 454.03 <5 5 Kjeldahl

Oil and Grease mg/L 794 <2 15 Gravimetric

Figure 8 Removal percentage for each parameter

4. CONCLUSION

Pempek wastewater contains high organic, suspended solid, nutrient, oil and grease content. A

combination of physical, biological and phyto-treatment can be used to treat these kinds of

wastewater. A complete WWTP can reduce COD up to 99.71%, BOD up to 99.76%, Nitrogen

up to 98.90%, Oil and Grease up to 99.75% from initial characteristic of wastewater.

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DESIGN AND APPLICATION OF WASTEWATER TREATMENT … · Pempek is one of Indonesia’s popular traditional foods, originated from Palembang City, Sumatra, Indonesia. Tasteful pempek

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