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7/29/2019 CALCIUM REMOVAL SYSTEM Pres. (4XD_wcb).ppt
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CALCIUM REMOVAL SYSTEM
(DE- CALCIUM SYSTEM)
PRESENTED BY:
ANGELO MAAMBONG AMISTAD
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DESIGN BASIS
ITEM UNIT VALUE
pH - 6.5 ~ 8.5
TSS ppm 10
Turbidity NTU 5.0
COD ppm 20
T- Alkalinity ppm 50TOC ppm 7.0
Si ppm 10
Na ppm >200
Ca ppm 700
Mg ppm 100
Fe ppm 0.05
Mn ppm 1.0
Cl ppm 20
SO4 ppm 2200
NO3 ppm 1.5
Al ppm 0.2
Ni ppm 0.01
Zn ppm
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PROCESS OVERVIEW
De- Ca
Reaction TankNo. 1
(224TK02)
De- Ca
Reaction TankNo. 2
(224TK03)
De- Ca Thickener(224TH01)
pH Adjust Tank(224TK04)
De- Ca Water Pond(224PD02)
Supernatant De- Ca Water
Na2CO3
CaCO3 (Recycled)
NaOHNaOH
PolyFerric Sulfate
PolymerNaOH H2SO4
CaCO3 (Sludge)
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DE- CA MAIN PROCESS AREA
224PD02224TH01
224TK04 224TK03 224TK02
pH Adjust Tank No. 2 Reaction Tank No. 1 Reaction Tank
De- Ca Water Pond De- Ca Thickener
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MAIN PROCESS DESCRIPTION
* REACTION TANK NO.1 (224TK02) *
Supernatant Water enters this tank Soda Ash (Na2CO3) and Caustic Soda (NaOH) are dosed into
this tank
10% NaOH is used to raise the pH between 10 ~ 11 (AIC-101)
10% Na2CO3 (dosing rate at 4.25 m3/ hr) is used as softener toreplace Ca2+ present in the wastewater
Overflow goes into Reaction Tank No. 2 (224TK03)
Main Chemical Reaction:
CaSO4 + Na2CO3 (slurry) Na2SO4 + CaCO3(s)( Supernatant Water)
Note: A large fraction of CaCO3 Sludge is recycled back to Reaction Tank No. 1 (224TK02).
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MAIN PROCESS DESCRIPTION* REACTION TANK NO. 2 (224TK03) *
Other than the overflow from Reaction Tank No. 1(224TK02), 10% NaOH, 10% Na2CO3 (valve is normallyclosed) and PolyFerric Sulfate (PFS or Fe2(SO4)3) aredosed into this tank.
10% NaOH is for pH control between 10 ~ 11 (AIC-102)before overflow goes into De- Ca Thickener (224TH01)
PFS (conc. = 335 mg/L & dosing rate at 1.2L/ min) is
used as coagulant
Overflow goes into the De- Ca Thickener (224TH01)
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MAIN PROCESS DESCRIPTION* DE- CA THICKENER (224TH01)*
Sedimentation and Bridging
Polymer PA331 (3 mg/ L, dosing rate at 8 L/ min) is
used in this unit
Settling sludge, CaCO3 slurry, is pumped out for reuse
or for recirculation back to Reaction Tank No. 1
(224TK02)
Treated water overflows to pH Adjust Tank (224TK04)
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*pH ADJUST TANK (224TK04)*
pH (AIC-103) of treated water is adjusted to 6.5 ~ 8.2
where NaOH and H2SO4 solution are used as adjusting
reagents
H2SO4 is dosed when pH > 8.2 and it is stopped when
pH < 7.7
NaOH is dosed when pH < 6.5 and it is stopped whenpH > 7.0
Treated water overflows to the De- Ca Water Pond
(224PD02)
MAIN PROCESS DESCRIPTION
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* DE- CA WATER POND (224PD02)*
Served as reservoir of De- Ca Water Supply
Softened water
Target Ca conc. 30 ppm
MAIN PROCESS DESCRIPTION
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DE- CA CHEMICALS
A) Sulfuric Acid (H2SO4)
B) Polyferric Sulfate or PFS (Fe2(SO4)3)
C) Caustic Soda (NaOH)
D) Soda Ash (Na2CO3)
E) Polymer (PA-331)
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CHEMICALS PREPARATION & FEEDING CHEMICAL CONSUMPTION
10% H2SO498% H2SO4 = 1,048 kg/ day
Dil. H2SO4 Storage Tank = 5 m3
Dil. H2SO4 Feed Pump = 3 m3/ hr x 15 m
10% NaOH
24% NaOH = 4,400 kg/ day
Dil. NaOH Buffer Tank = 5 m3
Dil. NaOH Feed Pump = 3 m3/ hr x 15 m
Polyferric Sulfate (PFS)
11% as Fe = 1,704 kg/ day
PFS Storage Tank = 2 m3
PFS Feed Pump = 0.8 L/ min x 20 m
Polymer
3 ppm x 200 m3
/ hr = 600 g/ hr600/ 0.1% = 600 L/ hr, 14400 L/ day
Polymer Tank = 5 m3 x 2 sets
Polymer Dosing Pump = 8 L/ min x 20 m
Na2CO3
10% Na2CO3 = 107 ton/ day
Slurry Tank = 30 m3 x 2 sets
Slurry Feed Pump = 4.2 m3/ hr x 15 m
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CHEMICALS PREPARATION & FEEDING
CHEMICALS PREPARATION
A) 10% NaOH
Dilution Tank (224TK08)
It has a capacity of 1.0 m3 where dilution of 24% NaOH to 10%concentration takes place.
Dilution Procedure:1) Fill the tank with the required amount of raw water by opening valve
224DIV043. Auto filling starts at LL level (7%) and stops at M2 level (68%).
2) Fill with required amount of 24% NaOH into the tank by opening valve224DIV039. Auto filling starts at M2 level (68%) and stops at H level(86%).
3) Agitator (224AG08) auto start to stir and stop after certain time.
Diluted NaOH Buffer Tank (224TK09)
The tank has a capacity of 5.0 m3 to handle 10% NaOH solution supplied
from NaOH Dilution Tank.
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B) 10% H2SO4
Dilution Tank (224TK10)
It has a capacity of 2.0 m3 where dilution of 98% H2SO4 to 10% concentrationtakes place.
Dilution Procedure:
1) Fill the tank with the required amount of raw water by opening valve 224DIV084.
Auto filling starts at LL level (23%) and stops at M2 level (88%).
2) Fill required amount of 98% H2SO4 into the tank by opening valve 224DIV081.
Auto filling starts at M2 level (88%) and stops at H level (94%).
3) Agitator (224AG10) auto start to stir and stop after certain time.
Diluted H2SO4 Storage Tank (224TK11)It has a capacity of 5.0 m3 to contain the 10% H2SO4 solution supplied fromDilution Tank.
CHEMICALS PREPARATION & FEEDING
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C) 10% Na2CO3
Mixing Tank (224TK05)
This tank has a capacity of 30 m3 where dissolution of powdered Na2CO3 to 10%
concentration takes place.
Dissolution Procedure:
1) Fill the tank with the required amount of raw water by opening VALVE V-196.
Auto filling starts at L level (7%) and stops at H level (91%).
2) Run Agitator (224AG05) to stir when level reaches 50%.
3) Fill required amount of Na2CO3 when agitator is running already.
Slurry Tank (224TK06/ 224TK07)Each tank has a capacity of 30 m3 and serve as storagetank for the 10% Na2CO3
slurry prior for feeding to Reaction Tank No. 1 (224TK02).
CHEMICALS PREPARATION & FEEDING
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DE- CA DCS SCREEN
The De- Ca operation has no DCS control or intervention.
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DE- CA LCP SCREEN
De- Ca operation is controlled via LCP.
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DE- CA LCP SCREEN
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DE- CA LCP SCREEN
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LOCAL CONTROL PANELS
De- Ca System Control Panel
Polymer Local Panel
(LCP-1)
Na2CO3 Mixing
Local Panel (LCP-2)
Door 1 Door 2 Door 3 Door 4
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MAIN PROCESS CONTROL SWITCH
AGITATORS & REDUCTION GEARS
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CONTROL VALVES & PUMPS
MAIN PROCESS CONTROL SWITCH
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NaOH DILUTION CONTROL VALVES, AGITATOR & PUMPS
DE- CA CHEMICALS CONTROL SWITCH
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H2SO4 DILUTION CONTROL VALVES, AGITATOR & PUMPS
DE- CA CHEMICALS CONTROL SWITCH
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DE- CA CHEMICALS CONTROL SWITCH
POLYFERRIC SULFATE OPERATION CONTROL VALVES & PUMPS
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SODA ASH OPERATION CONTROL VALVES, AGITATOR & PUMPS
DE- CA CHEMICALS CONTROL SWITCH
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DE- CA CHEMICALS CONTROL SWITCH
POLYMER OPERATION CONTROL VALVES, AGITATORS & PUMPS
GENERAL STEP BY STEP PROCEDURE IN LCP
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GENERAL STEP-BY- STEP PROCEDURE IN LCP
OPERATION
1) Switch ON Main Incoming Power. 2) Switch ON circuit breakers for LCP
Display Monitor and other breakers for
field instruments/ sensors.
LCP DisplayMonitor Circuit
BreakersField Sensor
Circuit Breakers
3) Switch ON circuit breakers of the specific
equipment or valve for operation.
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GENERAL STEP-BY- STEP PROCEDURE IN LCP
OPERATION
4) Turn the selector switch to the desired mode of operation.For dilution operation, turn the selector switch to ON mode.
5) Make the necessary adjustments on the settingsof flow or dosing rate and proceed to other De- Ca operation.
OPERATIONNORMAL OPERATION MODE
AGITATORS PUMPS CONTROL VALVES REDUCTION GEARS
A) De- Ca Main Process RUN AUTO AUTO RUN
B) Na2CO3 Operation RUN RUN (Transfer) AUTO -
AUTO (Feed)
C) NaOH Operation AUTO AUTO AUTO -
D) H2SO4 Operation AUTO AUTO AUTO -
E) PFS Operation - RUN (Loading) AUTO -
AUTO (Feed)
G) Polymer Operation (w/START button)
AUTO AUTO AUTO -
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OPERATING PROCEDURE
AGITATORS Selection switch to AUTO mode
- NaOH Dilution Tank Agitator (224AG08)
- H2SO4 Dilution Tank Agitator (224AG10)
- No. 1 Polymer Tank Agitator (224AG12)
- No. 2 Polymer Tank Agitator (224AG13)
Selection switch to RUN mode at start up
- No. 1 Reaction Tank Agitator (224AG02)
- No. 2 Reaction Tank Agitator (224AG03)
- Reduction Gear for Rake (224RG01)
- Reduction Gear for Coagulator A/B/C (224RG02A/B/C)
- pH Adjust Tank Agitator (224AG04)
- Na2CO3 Mixing Tank Agitator (224AG05)
Thickener (224TH01)
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PUMPS
Selection switch to AUTO mode
- De- Ca Water Pump A/B (224PU04A/B)
- CaCO3 Slurry Pump A/B (224PU06A/B)
- Diluted NaOH Transfer Pump A/B (224PU09A/B)
-
Diluted NaOH Feed Pump A/B (224PU10A/B)- Diluted H2SO4 Transfer Pump A/B (224PU11A/B)
- Diluted H2SO4 Feed Pump A/B (224PU12A/B)
- Na2CO3 Slurry Feed Pump A/B (224PU08A/B)
- Polymer Feed Pump A/B (224PU13A/B)
- Polyferric Sulfate (PFS) Feed Pump A/B (224PU14A/B)- De- Ca Area Sump Pump (224PU15)
Selection switch to RUN mode
- PolyFerric Sulfate (PFS) Loading Pump (224PU16)
OPERATING PROCEDURE
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TANKS AUTOMATIC VALVES
Switch auto valves to AUTO mode
NaOH
Dilution Tank Inlet Valve (XV-107)
No. 1 Reaction Tank Dosing Valves (XV-101 and XV-102)
No. 2 Reaction Tank Dosing Valves (XV-103 and XV-104)
pH Adjust Tank Dosing Valve (XV-106)
H2SO4 Dilution Tank Inlet Valve (XV-109)
pH Adjust Tank Dosing Valve (XV-105)
Raw Water Inlet Valve to NaOH Dilution Tank (XV-108)
Inlet Valve to H2SO4 Dilution Tank (XV-110)
OPERATING PROCEDURE
T
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pH METERS & OTHER INSTRUMENTS
pH
- Reaction Tank No. 1 (AIC-101= 10 ~ 11)- Reaction Tank No.2 (AIC-102= 10 ~ 11)
- pH Adjust Tank (AIC-103= 6.5 ~ 8.2)
Density
- Na2CO3 Mixing Tank (AIA-104= 1, 100 kg/ m3)
Flow
- FIQ-101
- FIQ-102- FI-103
- FI-104
Note: Monitor all level gauges/ sensors, pressure gauges and instrument air
supply.
OPERATING PROCEDURE
T
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DESIGN STREAMS FLOW RATE FOR PUMPS
A) De- Ca Water Pump (224PU04A/B) 200 m3/ hr
B) CaCO3 Slurry Pump (224PU06A/B) 45 m3/ hr
C) Dil. NaOH Transfer Pump (224PU09A/B) 3 m3/ hr
D) Dil. NaOH Feed Pump (224PU10A/B) 3 m3
/hrE) Dil. H2SO4 Transfer Pump (224PU11A/B) 3 m
3/ hr
F) Dil. H2SO4 Feed Pump (224PU12A/B) 3 m3/ hr
G) Na2CO3 Slurry Feed Pump (224PU08A/B) 6 m3/ hr
H) Polymer Feed Pump (224PU13A/B) 8 L/ minI) Polyferric Sulfate (PFS) Feed Pump (224PU14A/B) 1.2 L/ min
J) De- Ca Area Sump Pump (224PU15) 18 m3/ hr
OPERATING PROCEDURE
SUMMARY ON CHEMICAL REQUIREMENTS PER
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Chemicals
Optimum Tanks
Capacity(m3)
Required Weight/ Volume
Start- Up Operation Normal Operation
10% NaOH 1.02
Raw Water 647 L 546 L
24% NaOH 373 L 314 L
10% H2SO4 2.10Raw Water 1,976 L 1,411 L
98% H2SO4 124 L 89 L
10% Na2CO3 29.90
Raw Water 29.02 m3 26.4 m3
100% Na2CO3 3,289 kg (3.3 tons) 2,992 kg (3.0 tons)
0.1% Polymer 4.40 (per tank)
Raw Water 4,400 L 3,800 L
Polymer (PA-331) 4.49 kg 3.88 kg
Polyferric Sulfate (PFS) 2.00 -same- 1.6 m3
SUMMARY ON CHEMICAL REQUIREMENTS PER
DISSOLUTION/ DILUTION
ALARMS & COUNTERMEASURES
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ALARMS & COUNTERMEASURESGENERAL NATURE
OF ALARM
EQUIPMENT/
UNIT INVOLVED
CAUSE AUTOMATIC
RESPONSE
COUNTERMEASURES
1) TRIP
1) Tank Agitator
Overload
Not OperateCorrectly
Reset Breaker
2) Reduction Gear Stops operating Reset Breaker
3) Pump Stops operating
Check setting current againstrating current of motor andadjust main circuit breaker.
Check motor and mechanicalrotation of driving equipment.
2) HIGH LEVEL
1) De- Ca Water
Pond
The incoming flow
rate exceed designcapacity or;
Pump start
Check and control the
incoming flow rate.
2) De- Ca Area Sump Flow rate of pump(transfer or feed) isbelow the designcapacity.
Adjust the flow rate.
Stop Loading pump (for PFS
case only)3) Chemical Tanks
3) INSTRUMENT AIR
PRESSURE LOW
De- Ca Pneumatic
Operated valves.
No air supplied. Valves stop
functioning.
Check for air leakage/ supply.
4) HIGH pH
1) Rxn Tank No. 1 Excess dosage ofNaOH or Na2CO3.
-
Adjust the chemical dosagethru the needle valve at thedosage point.
2) Rxn Tank No. 2 Excess dosage ofNaOH.
-
3)pH Adjust Tank Insufficient dosageof H
2
SO4
soln. orexcess dosage ofNaOH.
-
ALARMS & COUNTERMEASURES
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GENERAL NATUREOF ALARM
EQUIPMENT/UNIT INVOLVED
CAUSE AUTOMATICRESPONSE
COUNTERMEASURES
5) LOW pH
1) Rxn. Tank No. 1 Insufficient dosage ofNaOH or Na2CO3.
-
Adjust the chemical dosagethru the needle valve at thedosage point.
2) Rxn. Tank No. 2 Insufficient dosage ofNaOH solution.
-
3) pH Adjust Tank Insufficient dosage ofNaOH or excessdosage of H2SO4.
-
6) HIGH DENSITY
Na2CO3 Mixing
Tank
Insufficient dosage ofraw water or excess
dosage of Na2CO3.
A) Reduce the charging orloading of Na2CO3.
B) Increase the raw water flowrate by opening XV-111.
7) LOW DENSITY
Na2CO3 Mixing
Tank
Insufficient dosage ofNa2CO3 or excessdosage of raw water.
A) Increase the charging orloading of Na2CO3.
B) Decrease the raw water flowrate by closing XV-111.
8) OVER TORQUE Reduction Gear for
Rake
Overload - Reset breaker
9) TORQUE HIGH Too thick or too muchof sludge.
- Discharge the sludge.
10) EMERGENCY
STOPLCP EmergencyStop Button
Emergency Stopbutton was pushed.
Stop Operation Reset the button.
11) EARTH LEAKAGE LCP Wire not properlyconnected.
- Reconnect the wire and resetELCB.
12) PUMP DRY Pumps in De- CaArea
Shortage of water orcontent.
Equipment stopsoperating.
Fill up the tank.
ALARMS & COUNTERMEASURES
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ENVIRONMENTAL BENEFITS
Reference
Timeframe
Wastewater/ Supernatant Circulation & Discharge
Tot. Discharge
from Tailings Dam(m3)
Recycle to Plant
(m3
)
Discharge to Pier
(m3
)
% Discharge
to Pier
TSS DISCHARGE
LOAD (kg)
Jan- Dec 2007 1,323,989.3 411,589.7 906,333.4 68.45 9, 063.3
Jan- Sep 2008 1,148,366.7 472,093.2 673,162.0 58.62 6, 731.6
Jan- Dec 2008 1,500,000.0
(Estimated)
600,000.0
(Estimated)
900,000.0
(Estimated)
60.00 9, 000.0
Jan- Dec 2009(w/ CBNH-2)
3,000,000.0
(Estimated)
2,784,000.0 216,000.0 7.2 2, 160.0
ADDITIONAL DATA: NO. OF OPERATING DAYS IN A YEAR = 315 DAYS
AVERAGE TSS DISCHARGE TO PIER = 10 ppm
% REDUCTION IN DISCHARGE TO PIER = 52.8 %
% REDUCTION IN TSS DISCHARGE LOAD = 76.0 %
DISCHARGE PERMIT FEE (CY 2008) = Php 55, 000. 00
DISCHARGE PERMIT FEE (CY 2009) = Php 20, 800. 00