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

Preliminary Primary Secondary Advanced

Process configuration, operation and maintenance

Oil separation

Coagulationsedimentation

DisinfectionActivated sludge

example

Influent-pollutants-concentration-flow rate-others

Effluent-pollutants-concentration-discharge-recycle-othersPerformance, maintenance, problems, energy

consumption, etc. and comments on the process

Appropriate process of wastewater treatment is selected based on the information and

data of material flow on the production process and the information such as;

1)Existing water pollution problems, and those expected in the water body,

2)Environmental awareness and outlook/vison of plant manager/administrator, and

3)Surrounding environment and public awareness.

✖

Appropriate choice of

wastewater treatment process

Recycle use

Discharge

7

Kurita Water & Environmental Foundation

Countermeasures for industrial wastewater(4)For sustainable water use in development

✖

Appropriate wastewater treatment

with low cost and low consumptions

of energy and additional resources.

Discharge

Sound water environment

Effective use of limited water resources

Recycle use

Resources and energy saving

Domestic materials and energy input

Products

Increase of productivity

Decrease of wastes and wastewater discharge

Process and plant improvement

Watershed or regional area

Wastes, wastewater, exhaust gas

8

Balance & Flow：Material, Energy, Momentum, Cash ･･

Rate：Mass transfer, Reaction,････････Unit Operation：Separation & refining, mixing, other treatments･･

Process & System: Development and design, Analysis and

Evaluation, Operation and Control, Management

Chemical engineering approach for diagnosis of industrial process and plants

Chemical engineering aspects - mass & energy balances; choice of datum, overall & component

balances, simultaneous mass & energy balances, stoichiometry, combustion, recycle & purge

streams: fluid flow; dimensionless groups, viscosity, streamline & turbulent flow, Reynolds

number, roughness, energy losses: pumps; flow-head characteristics, sizing: heat transfer;

conductivity, resistance, overall heat transfer coefficients, fouling factors, heat exchangers: unit

operations; definition, categorization, typical applications: flow sheets: safety & environmental

aspects of plant design & operability.

Principles of chemical engineering

9

Reaction： A → R is proceeded in a single stage reactor

Input Output

Volumetric Efficiency=Q(CR1-CR0)/V1

Conversion :x=1-CA1/CA0

Energy for

operation

Q

liquid volume:V1

θ : hydraulic retention time)

Q Q

CA0=10

CR0=0

CA1=5

CR1θ =1h

Q

liquid volume:V1

θ : hydraulic retention time)

Q Q

CA0=10

CR0=0

CA1=5

CR1θ =1h

reactor

Material balance equation of

reactant A in reactor

Material Flow (or Balance) Analysis in a Reactor

Material flow analysis in production process

Reactant: AMixture ofProduct: R

Residual reactant: AIntermediates: IBy-products: X, etc.

10

recycle

Wastewater 2 wastes２wastes１ Wastewater 1

Energy

Raw material

Products

Wastes & wastewater

reactor

separationseparation

mixing

Reservoir Wastes 3

Amount and composition of wastes and wastewater can be clarified

What kind of and how much materials coming in and going out at each unit operation can be known!

Material flow analysis on the process will give information of:Productivity, yield, wastes & wastewater discharge, etc.

separation

Material flow analysis on industrial process

1)MFA on industrial process

11

Electro deposition

Evaporation

ProductsProducts

Previous process

Improvement of industrial process for the reduction of wastewater discharge

Washing water

Wastewater

12

Recycle use

Electro deposition

Water supply

Evaporation

Products

Wastewater

Products

With incorporation of UF membrane, the filtrate can used for products washing.

Closed process can be achieved for electro-deposition.

Previous process

Improvement of industrial process for the reduction of wastewater discharge

UF

EvaporationProcesswater

Recycle use

Products

Recycle use

Electro deposition

Products

Improved process

featured UF filtration

13

Onsite treatment and recycle of wastewater in unit industrial process

APROCESS PROCESS PROCESS PROCESS

RAW MATERIAL

ION

EX

CH

AN

GE

FIL

TR

AT

ION

BL

OW

WA

TE

R

COAGULATION

SE

DIM

EN

-

TA

TIO

N

PRODUCT

ACTIVATED CARBON

EFFLUENT

RECYCLE

FIL

TR

AT

ION

BL

OW

WA

TE

R

BL

OW

WA

TE

R COAGULATION

FILTRATION

Process

Water

B C D

Simple onsite

treatment and recycle

Simple treatment of

mixed similar wastewater

Final treatment in small

process for discharge

and recycle

Recycle

Recycle

Recycle

14

Process

A

Process

B

Process

C

Process

D

Raw materials Products

b' eSimple and

advanced treatment

Effluenta'

Similar wastewater

Novel and advanced wastewater treatment and recycle system

To meet the stringent effluent

standard, additional and high

cost treatments are needed.

Reduction in process water use

Mixing of wastewater makes the treatment difficult and increases the cost of treatments

Previous system

Mixed wastewater

Process

A

Process

BProcess

CProcess

D

Raw materials Products

Effluent

Process water

SecondaryPrimary Advanced

Simple and small

treatment is

enough to meet the

effluent standard

Advanced wastewater treatment and recycle

system of industries based on material flow analysis

15

Supply and recycle system of ultra pure water

by onsite treatment in electronics industries

Rawmaterial

Waterrecovery

Mainprocess

PackagingProducts

Wastewatertreatment

Ultra purewater

Pre-treatmentfiltration

Pure water

Wash & rinse

Wash& rinse

Industrial waterwell water

Cooling water

Boiler waterPrimaryprocess

LCDSemi-conductor

recycle water

Functionalwater

Huge ultra pure and functional water are used in the electronic industry, while the most

is recycled after sequential treatment. A little water is needed for the process operation.

RO: Reverse Osmosis

MF: micro-filtrationUF: ultra-filtration

Continuous Ion Exchange

Protection of Intellectual Properties

16

Amount and composition of wastes and wastewater can be clarified

Material flow analysis on the process will give the information on:raw material, reactants, products, inert, by-products, intermediates, etc.

Material flow analysis on industrial process

Improvement of production process(1)Essential information and data for the improvement

1)Improvement :conversion, yield, productivity, quality, etc.

2)Reduction : discharge of wastes and wastewater, energy consumption17

Products Processing Wastewater(l) BOD(g) COD(g)Oil &

Grease(g)SS(g)

Engine,Chassis Machining 20 - 200 145 100 - 700 80 10 - 400

Body Painting 1230 - 4100 300 - 900400 - 700 24 - 85100 -400

Brake Forging & Painting 30 - 390 0.14 - 6.71.0 - 13.41.6 - 26.82 - 40

Electroplating 20 - 70 0.86 0.42 - -

Transmission Casting 10 - 320 - 1 - 46 - 0.5 - 45

Pollutants discharge from automobile manufacturing plant

Improvement of production process(2)Characteristics of wastewaters from industrial process

18

Unit process

COD is CODMn

(BOD/CODMn)

＊

Kitchen and toiletwastewaters

Effluent quality standard applied

COD<10 mg/L in average

COD<15 mg/L in maximum value

Effluent

Mixing

Activatedsludge

Sandfiltration

Activatedcarbon(AC)adsorption

Oil-waterseparation

CoagulationFloatation

Machining

Casting

Forging

Others

Rainfall, etc

wastewaters

72m3/d

743mg/L36m3/d

2309mg/L

16m3/d

3227mg/L

1955m3/d90mg/L

41m3/d

171mg/L

(1.06)

2120m3/d

235m3/d

66.8mg/L

2355m3/d

69.5mg/L

(1.03)

＊37.9mg/L

35.5mg/L

(0.26)

BOD<5mg/L

COD:8.4mg/L

(0.595)

Improvement of production process(3)Identification of problems in the existing process

Refractory chemicals (pollutants) remain in the wastewater

High COD loading to AC adsorptionHigh operating cost of AC adsorption

System configuration and material flow in wastewater treatments of automobile factory

19

Eluent : Water

Flow rate: 1 ml/ min

Column: MCI GEL CQP10

Injection volume: 20 µl

252015105

DO

C (

mg/ｌ）

10 1 0.15 0.5 x103

MW=7000

( BOD/DOC=0)

MW=250

(MW)

Influentwastewater

Effluent

Elution Time (min)

0

10

20

30

40

50

BOD/COD ratio: Biodegradability

Analysis of molecular size distribution and biodegradability of pollutants contained in wastewater.

Pollutants remained in the effluent of biological treatment

Why the pollutant with

MW=7000 exists in the

wastewater from machining

process?

1)It was due to the continuous

leakage of hydraulic oil from

hydraulic cylinders to operate

machining tool.

2）Principal ingredient of non-

mineral hydraulic oil was

polyethylene glycol(PEG).Refractory chemicals

Removed by biological treatment

This material should be removed from the raw and auxiliary materials in the production process

Improvement of production process(4)Identification of pollutants to be removed

20

Bio

-degra

dabili

ty(B

OD

/ThO

D)

Molecular Size (MW)

102

103

104

105

0

1.0

0.8

0.6

0.4

0.2

ThOD:Theoretical Oxygen Demands

Coagulation with

Sedimentation or

Flotation

Membrane

Filtration

Biological Treatment

Adsorption by

activated carbonChemical

oxidation?

Selection of applicable wastewater treatments for organic pollutants based on molecular size and biodegradability

Improvement of production process(5)Characterization of pollutants to be removed

21

Effluent quality

Raw Materials, Process Wastewater

Bio-degradability

YesCoagulation or gravitational separation

Effluent quality Yes

No

Yes

Yes

Yes

No

Effluent (recycle, discharge)

Activated carbon adsorption, etc.

No

Organic removal Improvement of

biodegradability

Reduce utilization

No

Filtration, Membrane separation(flux, fouling, energy, life)

No

Yes

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

Process Wastewater

Property of suspended solids

size(μm) polaritySpecific gravity

SedimentationStarch, flour-milling

pulp & paper1～103 low 1) >1

FloatationBean curd & its

deep-fried, rubber- low 2) <1

Pressurized floatation

Pulp & paper

cleaning- low 2)

<1

or =１

CentrifugePig manure, paint-

production10-1～102 low 1) -

Coagulation Food, electro-plating 10-3～1 - -

Filtration Food, electro-plating 10-3～10 low 5) independent

43