13 th Annual Meeting of WEPA WEPA International workshop on Industrial Wastewater Management Koichi FUJIE, Professor Institute of Advanced Sciences Yokohama National University Sept.26, 2017, Jakarta, Indonesia Sustainable Water Use in Development of Asian Countries Evaluation and Control of Industrial Wastewater Discharge based on Material Flow Analysis 1
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13th Annual Meeting of WEPA
WEPA International workshop on Industrial Wastewater Management
Koichi FUJIE, Professor
Institute of Advanced Sciences
Yokohama National University
Sept.26, 2017, Jakarta, Indonesia
Sustainable Water Use in Development of Asian Countries
Evaluation and Control of Industrial Wastewater
Discharge based on Material Flow Analysis
1
Contents of this presentation
Categorization of industries
Process configurationInput/outputMaterial flow in the process
Kind of wastewater Kind of treatments
Conditions of surrounding environments
Kind of production process
Improvement of productionReduction of wastewater
Appropriate selection and operation of treatments
Recycle use for what?
(characterization)
Impact on environment and ecosystem
2
Water resource
Costal area
Flow rate &environment condition
Environment quality standard
Water pollution load
Effluent standard
Monitoring
Watershed management Wide variety of industries
Information on industrial activities in the watershed such as type of industry, water use and wastewater discharge, pollutants, treatment, recycle, and so on.
Impact on river water quality
Water flow and use in watershed
Daily life
Sewage treatment
Water intake & distribution
Treatment? Treatment& recycle?
Flow rate, pollutants and concentration, etc.
Agriculture
Process improvement and reduction of wastewater are required.
Appropriate treatment is required for the conservation of water environment and water resources with low cost and low consumptions of energy and materials.
3
W astewater
Screening
Oil Separation
pH Control
Preliminary Treatment
Primary
Sedimentation
Coaguration
Floatation
Secondary
Activated Sludge
Trickling Filter
Submereged Filter
Rotating Biological
Contactor
Advanced Treatment
Biological Treatments
Coagulation/Sedimentation
Stripping
Sand Filtration
Ultrafiltration
Microfiltration
Reverse Osmosis
Chemical Oxidation
Disinfection
Electrodyalisis
Ion Exchange
Effluent
Configuration of wastewater treatment process: Combination of various unit separation process based on the given conditions of wastewater and treatment.
Wastewater treatment process
1)Wastewater treatment is a separation process.Simple composition and/or similar properties of pollutants are the better for separation.
2)Selection and combination of unit process can be done based on the conditions as the quality and quantity of influent, effluent quality, and other requirements.
3)We have to know the wastewater for the appropriate selection and combination of unit process, and that the construction and operation of the wastewater treatment process consumes energy and additional materials. Trade-off!
4
Typical industries in the watershed
Industry and production process Related information and data to be collected
Public water body
1)Type of industry, raw materials and products2)Production process and material flow3)Wastes and wastewater discharge4)Environmental problems5)Environmental awareness and outlook of operator6)Surrounding environment and public awareness
Countermeasure for industrial wastewater(1) Categorization of industrial process
1)Operational condition of the industrial plant
2)Source of wastewater and the its information
3)Identification of pollutants and treatability, etc.
5
Countermeasure for industrial wastewater(2) Performance improvement of industrial plant
Industrial process and plant
Industry and production process Information on the plant performance
Material flow analysis on the plant will give;1)Conversion of raw materials,2)Yield of product and productivity, 3)By-products and wastes.
These information and data can be used to diagnose the process and plant.Optimal operating conditions will be given to reduce the pollutants discharge, while increasing the production performance.
6
Kurita Water & Environmental Foundation
Countermeasures for industrial wastewater(3)Selection of appropriate wastewater treatments
Biodegradability and bio-treatablity testBOD/TOC, BOD/ThOD, BOD/COD
> x Good for biological treatment < y Not good for bio-treatments
Effluent quality
Chemical
oxidation Yes
No
No
Procedure to determine appropriate treatment of organic pollutants
Evaluation of pollutants in terms of coagulation, filtration,biodegradation, chemical oxidation, adsorption.
22
Procedure to evaluate the physico-chemical technologies for suspended solids removal
Effluent
YesQuality
Size Screen
wastewater
Next stage treatment
Molecularsize
QualityYes
Filtration
Quality Yes
PolaritypH control+coagulation
Centrifuge P. floatation
QualityYes
Specificgravity Floatation
YesQuality
Sedimentation
23
エアレーションタンク最初沈殿池 最終沈殿池 塩素滅菌槽 放流
ポンプ
返送汚泥
余剰汚泥
生汚泥
焼却炉
脱水機
焼却灰
埋立て
汚泥消化 濃縮
脱水ケーキ
沈砂池スクリーン
脱離液
下水
空気
高度処理
再利用
screen
Advanced treatment
Primary
sedimentation
tank
aeration
tank
Secondary
sedimentation
tankDis-
infection
sludgetreatment
sludgeincineration
recycle
sewageSand separation
Activated sludge process for wastewater treatment
Energy consumption in activated sludge process
24
Month & Year Jan. 1965 Jan 1973 Nov. 1973 Feb. 1974
Wastewater
(m3/t-polymer) 36.2 17.0 8.8 0.2
Counter
measure (A) (B) (C)
(A) Increase the polymer concentration in the reactor,
(B) Wastewater recycle from polymer separation process,
(C) Wastewater recycle from catalyst washing and polymer drying processes.
Improvement of production process(6)Experience in polymer production for wastewater reduction
Countermeasures in polymer production process to reduce wastewater
discharge by enhanced recycle of recovered effluent from each unit
process and by increase of polymer concentration in the reactor.
Production rate of polymer in the reactor
was increased
25
3002001000Relative value to '75
Production
Water use
Water use/Production
BOD discharge
COD discharge
SS discharge
Wastewater Discharge from Paper and Pulp Mills
Improvement of production process(7)Reduction in water use and pollutants discharge
This figure shows the transition in water use and pollutants discharge in pulp industry.
26
This figure shows the transition of process water use for ¥1 million
($10,000) production in various industries. Water use was sharply
decreased around 1973!
Energy crisis@1973Energy crisis@1973
Improvement of production process(8)Reduction of water use in production process
27
Energy crisis@1973 Energy crisis@1973
This figure shows the increase in used water recovery for recycle in
industry. The energy crisis in 1973 and 1978 triggered the increase of
recycle ratio of recovered effluent after appropriate treatment.
Improvement of production process(9)Increase of water recycle ratio in industrial production
28
(×108m3/y)
Recycle ratio
Recycled water
Fresh water Intake
Wate
r use f
or
industr
y
Wate
r re
covery
and
recycle
use
Low contaminated effluent was preferentially
recycled after simple treatment.
Improvement of production process(10)Use of water and recycle in industries of Japan
29
79 84 89 94 990
1000
2000
産業系
生活系
その他
西暦年度
発生
汚濁
負荷
量(t
/日) 663
(37.0)
961 (53.5)
170 (9.5)
551 (34.5)
883 (55.2)
164 (10.3)
529 (36.1)
783 (53.5)
152 (10.4)
数値:上段(t/日) 下段(%)
437 (34.3)
696 (54.7)
140 (11.0)
429 (35.6)
637 (52.8)
138 (11.6)
Pollution loadupper (t/d)lower (%)
Year
Pollu
tio
n loa
d(t
/d)
Industrial
Domestic
Others
Figure shows the transition in reduction of COD loading into
closed sea area in Japan.
Improvement of production process(11)COD loading into closed sea area in Japan
30
Top priority for the sustainable water use in development is the
improvement of the production process
1)Analyze materials & energy flow in industrial production
process for diagnosis and to clarify the appropriate
countermeasure.
2)Before considering the treatment of wastes and wastewater,
improve the industrial process to minimize emission.
3)Select appropriate treatment technology and process based
on characterization of wastes and wastewater, and then
recycle after treatment.
Improvement of production process(12)Top priority for the sustainable water use in development
31
Improvement of production process(13)Management system for the stock and flow of chemicals
Report on materials: purchase & consume
Permission to purchase
Application for the permission to purchase materials
Factory for Industrial Production
Environment
Management HQ
Database of materials used in
production process in terms
of stock and flow
Environment management division can estimate the followings based on the information in the above:1)Composition of wastewater and the amount from the plant,
2)Appropriate treatment method for the wastewater,
3)Approach how to reduce the environment loading and the impact from the production process
Secondary materials: paint, lubricant,
coolant, detergents, hydraulic fluid, etc.
Supplier
Raw materials, secondary materials
Information of materialsSupply
materials
32
Palm oil mill (North Sumatra)
Material flow analyses of biomass, biomass residue and wastewater in plantation of palm oil and cassava for sustainable cultivation of crops.
Application of Material Flow AnalysisMFA in plantation for appropriate use of biomass residues
Tapioca mill (Lampung)
33
Onggkok26~42 t-C/d
Tapioca
56 t-C/d(weight 140-150t/d)
COD:18,000~25,500
(mg/ℓ)
Cassava
140 t-C/d(weight 700-750 t-wet/d)
Skin, tips10~14 t-C/d
100%
oil
6,750 ℓ/d
electricity
34.5MWh/d
water2,630 m3/d
Lagoon
Methane gas
Tapioca mill
26~40%
40%
Flow:3,000 m3/d
20~22%
Cassava yield:13t/ha
wastewater
28~30 t-C/d
Application of material flow analysisOrganic carbon flow in tapioca mill
34
Skin & tip8.1 kg
(1.0 kg-C)(0.02 kg-N)
Onggok102 kg
(40 kg-C)(0.4 kg-N)
タピオカ204 kg
(71.6 kg-C)(0.15 kg-N)
Elot
12 kg(4.4 kg-C)
(0.11 kg-N)
(108 kg-C) (1.34 kg-N)
1 t-cassava(164 kg-C)(1.26 kg-N)
処理水2.2m3
washing & peeling
crashing
separation
tapioca
residueprocess water wastewater
Carbon and Nitrogen flow in tapioca mill for 1 ton cassava processing (wet base)
2.4 m3
(46.7 kg-C)(0.43 kg-N)
Application of material flow analysisOrganic carbon and nitrogen flow in tapioca mill
35
36
Wastewater
400kg-C/h
Products:9.66t/hPalm oil: 8.72t/h
Kernel oil:0.94t/h
EFB8.6t/h
Steam
electricity
Lagoon
Boiler
For effective
use
COD:31000g/m3
GHG
emission
Flow:33.7m3/h
FFB:40t/h
Fiber(moist.)4.9t/h
Shell(dry)2.0t/h
Shell(moist.)0.24t/h
Kernel shell2.6t/h
Application of material flow analysisWet weight base material flow in palm oil mill
36
37
Electricity
Steam
Raw material
Biomass residue POME
7 kg-C
(354kg)
FFB
307 kg-C
(1,000 kg)
Products
CPO
163 kg-C
(215 kg)
EFB
38 kg-C (250kg)
COD 50,000 mg/ℓ
POM
34.4% 2.2%
100%
For POM
operation
PK
32 kg-C
(43.0kg)
Boiler
Shell
24 kg-C(54kg)
Fiber
44 kg-C (141kg)Lagoon
63.4%
Shell 13kg-C
Fiber 38kg-C
()moistened organic matter for FFB1,000kg
1)53 % of organic carbon in FFB is retained in CPO
2)77% of organic carbon flow into lagoon is biogas, 42% is methane.
CH4
42%
CO2
35%
100.0%Effluent
9%
Biogas
sediment*
14%
CO2
77%
Application of material flow analysisOrganic carbon flow in a palm oil mill (POM)
37
Tapioca (Cassava)
Org
an
ic c
arb
on
in
waste
wate
r
[kg
-C/t
on
]
38~41
190~205
0
100
200
Cane sugarPalm oil
0.3~0.69.2~9.8
42~45
3.5~7.1
Entire energy
from outside No energy from outside
per 1ton of raw material
per 1ton of product
Amount of organic carbon discharge from agro-industries into wastewater per one ton of products.
Huge organic carbon is discharged from tapioca mill into wastewater
Application of material flow analysisDischarge of organic carbon from agro-industries
38
edimentation
8,000
25%100%
Biogas 0.60tonCH4 14%(35%)
CO2 26%(65%)
-Flow rate
400m3/day
-COD
31,550ppm
35%
Pond No.1
Sedimentation
COD8,000ppm
1.2t-C/day
Inlet Pond No.3
4.7t-C/day
25%
12%
Pond No.2
40%
COD ?ppm
1.5t-C/day
100%
Biogas 1.9ton-C/day
Biogas 0.60t-C/day
Biogas 53%
CH4 9%(67%)
CO2 4%(33%)13%
Application of material flow analysisCarbon flow in palm oil mill lagoon
39
Biomass residue
4.3 kg/day(1.6 kg-C)
(0.03 kg-N) Excreta
4.4 kg/day(1.8 kg-C)
(0.08 kg-N)
Fattening period
6 months
Daily weight increase
0.4 kg/day(0.2 kg-C)
(0.02 kg-N)
Breathing・burp
1.0 kg/day(0.3 kg-C)(0 kg-N)
Compression residue,sediment, skin, etc.
Corn1.1 kg/day(0.4 kg-C)
(0.04 kg-N)
Auxiliary feed0.7 kg/day(0.3 kg-C)
(0.03 kg-N)
Additional feedComposting
0.8 kg/dayRice husk
Compost
3.3 kg/day(1.2 kg-C/day)
(0.09 kg-N/day)
Carbon and Nitrogen flow in cattle fattening using biomass residue of tapioca mill as feed
Application of material flow analysisCarbon and nitrogen flow in cattle fattening
40
Summary of this presentation
Categorization of industries
Process configurationInput/outputMaterial flow
Kind of wastewater Kind of treatments
Conditions of surrounding environments
Kind of production process
Improvement of productionReduction of wastewater
Appropriate selection and operation of treatments
Recycle use for what?
(characterization)
Impact on environment and ecosystem
41
Thank you for your kind attention!
City of Yokohama
Sustainable Water Use in Development of Asian Countries
42
Suspended solids removal from industrial wastewaters