F&N DAIRIES MANUFACTURING (MALAYSIA) SDN BHD PRACTICAL TRAINING REPORT

TITLE: FACILITIES SYSTEM OPERATIONS & CHEMICAL TREATMENT STUDIES

NAME: NAVAGANESH KANNAPPEN DEPARTMENT: ENGINEERING SERVICES - FACILITIES SUPERVISOR: MR. LAU LAY CHER TRAINING PERIOD: SEPT 2013 DEC 2013

This Internship Training report is submitted in partial requirement for the successful completion of the Cooperative Placement at F&N Dairies Manufacturing Sdn Bhd. This report covers the operations of the main systems in F&N Dairies Manufacturing Sdn Bhd, the common problems and the suitable chemical treatment to overcome those problems.

Navaganesh Kannappen UCSI University Kuala Lumpur, Malaysia December 2013

BOILER SYSTEM CHEMICAL TREATMENT

The function of a boiler is to transfer heat from hot gases generated by the combustion of fuel into water until it turns to steam. The steam or hot water can then be used in building or facility processes. Boiler feed water often contains impurities, which impairs boiler operation and efficiency. Chemical additives can be used to correct the problems caused by these impurities. To improve feed water quality, and steam purity, these chemicals can be injected directly into the feed water or steam.

Benefits of Chemical Treatments

Increase boiler efficiency Reduce fuel, operating and maintenance costs Minimize maintenance and downtime Protect equipment from corrosion and extend equipment lifetime

List of Problems Caused By Impurities in Water

Basic Boiler System Schematic

Boiler Waterside Fouling

Scale is one of the most common deposit related problems.

build-up of solid material from the reactions between the impurities in water and the water-side tube surface.

acts as an insulator that reduces heat transfer - causing a decrease in boiler efficiency and excessive fuel consumption.

overheating of tubes and potential tube failure (equipment damage).

Oxygen Attack

Oxygen attack is the most common causes of corrosion inside boilers.

dissolved oxygen in feed water can become very aggressive when heated reacts with the boilers internal surface to form corrosive components on the metal surface.

can cause further damage to steam drums, mud dams, boiler headers and condensate piping.

Oxygen attack is an electrochemical process that can be described by the following reactions:

Anode: Fe Fe
2+

2e

Cathode: O2 + H 2O + 2e

2OH

Overall: Fe + O2 + H2O Fe(OH)2

Acid Attack

Acid attack is another common cause of corrosion. Low makeup or feedwater pH can cause serious acid attack on metal surfaces in the preboiler and boiler system. Even if the original makeup or feedwater pH is not low, feedwater can become acidic from contamination of the system. Common causes include the following:

improper operation or control of demineralizer cation units process contamination of condensate cooling water contamination from condensers

Acid corrosion can also be caused by chemical cleaning operations. Overheating of the cleaning solution can cause breakdown of the inhibitor used, excessive exposure of metal to cleaning agent, and high cleaning agent concentration. Failure to neutralize acid solvents completely before start-up has also caused problems. In a boiler and feedwater system, acidic attack can take the form of general thinning, or it can be localized at areas of high stress such as drum baffles, "U" bolts, acorn nuts, and tube ends.

happens when the pH of feed water drops below 8.5.

carbonate alkalinity in water is converted to carbon dioxide gas (CO2) by the heat and pressure of the boilers.

CO2 is carried over in the steam. When the steam condenses, CO2 dissolves inwater to form carbonic acid (H2CO3) and reduces the pH of the condensate returning to the boilers.

may also impact condensate return piping throughout the facility.

Treatment

Oxygen Scavengers

A deaerator removes most of the oxygen in feedwater; however, trace amounts are still present and can cause corrosion-related problems. Oxygen scavengers are added to the feedwater, preferably in the storage tank of the feedwater, to remove the trace mount of oxygen escaped from the deaerator. The most commonly used oxygen scavenger is sodium sulfite. Sodium sulfite is cheap, effective and can be easily measured in water.

Hydrazine or organic oxygen scavengers are normally used. In these applications, the increased dissolved solids contributed by sodium sulfate (the product of the sodium sulfiteoxygen reaction) can become a significant problem. Also, sulfite decomposes in highpressure boilers to form sulfur dioxide (SO2) and hydrogen sulfide (H2S). Both of these gases can cause corrosion in the return condensate. Hydrazine has been used for years as an oxygen scavenger in high-pressure systems and other systems in which sulfite materials cannot be used. Hydrazine is a reducing agent that removes dissolved oxygen by the following reaction:
N2H4 hydrazine + O2 oxygen 2H2O water + N2 nitrogen

In addition to its reaction with oxygen, hydrazine can also aid in the formation of magnetite and cuprous oxide (a more protective form of copper oxide), as shown in the following reactions:

N2H4 hydrazine

6Fe2O3 hematite

4Fe3O4 magnetite

N2 nitrogen

2H2O water

and

N2H4 hydrazine

4CuO cupric oxide

2Cu2O cuprous oxide

N2 nitrogen

2H2O water

Lime Softening and Soda Ash

Lime is added to hard water to precipitate the calcium, magnesium and, to some extent, the silica in the water. Soda ash is added to precipitate non-bicarbonate hardness. The process typically takes place in a clarifier followed by a hydrogen cycle cation exchange and a hydroxide cycle anion exchange demineralization.

Neutralizing Amines

Neutralizing amines are high pH chemicals that neutralize the carbonic acid formed in the condensate (acid attack). The three most commonly used neutralizing amines are morpholine, diethyleminoethanal (DEAE) and cyclohexylamine. Neutralizing amines cannot protect against oxygen attack; however, it helps keep oxygen less reactive by maintaining an alkaline pH. Neutralizing amines may be fed to the storage section of the deaerating heater, directly to the boiler with the internal treatment chemicals, or into the main steam header. Some steam distribution systems may require more than one feed point to allow proper distribution.

Neutralizing amines are usually fed based on condensate system pH and measured corrosion rates. These amines may be fed neat, diluted with condensate or demineralized water, or mixed in low concentrations with the internal treatment chemicals.

Chemical Used for Boiler in F&N DAIRIES

PRODUCT NAME OPTISPERSE SP 8100 CORTROL IS 1075 OPTISPERSE ADJ 5050 OPTISPERSE PO 5083 PDV SALT STEAMATE FM 1003

NAME OF CHEMICAL (ACTIVE INGREDIENT) Phosphate Sodium sulphite Sodium Hydroxide Sludge conditioner Sodium chloride Lecithin

OPTISPERSE ADJ 5050 ADJ 5050 is used for internal boiler treatment. It is a polymer in aqueous alkaline solution. It is a 50% caustic soda solution used to control boiler water alkalinity. Because this product is a liquid, the hazards associated with dissolving dry caustic soda are significantly reduced.

CORTROL IS 1075

IS 1075 is an inorganic chemical scavenger used to control pre-boiler and boiler oxygen corrosion. It is a dry, white powder of sodium sulphite, specially catalyzed to provide instantaneous oxygen removal in boiler feed water systems. CorTrol IS1050 controls oxygen corrosion in boiler systems as well as in hot and cold water systems. CorTrol IS1050 is used because it:

1. reacts rapidly with dissolved oxygen 2. is easy to apply and control 3. provides good system protection

When applied to the pre-boiler or boiler system, CorTrol IS1050 protects metal surfaces from oxygen attack.

PDV SALT

Pure dry vacuum salt is primarily used for brining process. It is composed of sodium chloride.

STEAMATE FM 1003

It is a mixture of aqueous solution of lecithins. It is a blend of neutralizing amines with selected stability and vaporization characteristics. It volatilizes with the steam and quickly neutralizes the acidic components of steam. It provides controlled protection at points of initial condensation and in the extended areas of a complex steam condensate system. This reduces the pickup of copper and iron corrosion products.

COOLING WATER SYSTEM CHEMICAL TREATMENT

Water is used in cooling systems as a heat transfer medium and frequently also as the final point to reject heat into the atmosphere by evaporating inside cooling towers. Depending on the quality of available fresh water supply, waterside problems develop in cooling water systems from: Scaling Corrosion Dirt and dust accumulation Biological growth Any of these problems or more usually a combination of them result in costly unscheduled downtime, reduced capacity, increased water usage, high operation and maintenance costs, expensive parts replacements, and acid cleaning operations which reduce the life of the cooling system. Selection of water treatment program for a specific system depends on: 1. System design, including system capacity, cooling tower type, basin depth, materials of construction, flow rates, heat transfer rates, temperature drop and associated accessories. 2. Water, including make up water composition / quality, availability of pre-treatment and assumed cycle of concentration. 3. Contaminants, including process leaks and airborne debris. 4. Wastewater discharge restrictions. 5. Surrounding environment and air quality.

The critical parameters for cooling water are: conductivity, total dissolved solids (TDS), hardness, pH, alkalinity and saturation index.

Corrosion Problems Factors Many factors affect the corrosion rates in a given cooling water system. Few important factors are:

1. Dissolved Oxygen - Oxygen dissolved in water is essential for the cathodic reaction to take place.

2. Alkalinity & Acidity - Low alkalinity waters have little pH buffering capability. Consequently, this type of water can pick up acidic gases from the air and can dissolve metal and the protective oxide film on metal surfaces. More alkaline water favours the formation of the protective oxide layer.

3. Total Dissolved Solids - Water containing a high concentration of total dissolved solids has a high conductivity, which provides a considerable potential for galvanic attack. Dissolved chlorides and sulphates a particularly corrosive.

4. Microbial Growth - Deposition of matter, either organic or inorganic, can cause differential aeration pitting (particularly of austenitic stainless steel) and erosion/corrosion of some alloys because of increased local turbulence. Microbial growths promote the formation of corrosion cells in addition; the byproducts of some organisms, such as hydrogen sulphide from anaerobic corrosive bacteria are corrosive. 5. Water Velocity - High velocity water increases corrosion by transporting oxygen to the metal and carrying away the products of corrosion at a faster rate. When water velocity is low, deposition of suspended solids can establish localized corrosion cells, thereby increasing corrosion rates.

6. Temperature - Every 25-30F increase in temperature causes corrosion rates to double. Above 160F, additional temperature increases have relatively little effect on corrosion rates in cooling water system.

Some contaminants, such as hydrogen sulphide and ammonia, can produce corrosive waters even when total hardness and alkalinity are relatively high.

Treatment Methods Most corrosion control strategies involve coating the metal with thin films to prevent free oxygen and water from coming into close contact with the metal surface. This breaks the reaction cell, and reduces the corrosion rates. Several major chemical treatment methods can be used to minimize corrosion problems and to assure efficient and reliable operation of cooling water systems.

1. Anodic inhibitor 2. Cathodic inhibitor 3. Mixed inhibitor

Corrosion Inhibitors A corrosion inhibitor is any substance which effectively decreases the corrosion rate when added to an environment. An inhibitor can be identified most accurately in relation to its function: removal of the corrosive substance, passivation, precipitation, or adsorption. Deaeration (mechanical or chemical) removes the corrosive substance-oxygen. Passivating (anodic) inhibitors form a protective oxide film on the metal surface. They are the best inhibitors because they can be used in economical concentrations, and their protective films are tenacious and tend to be rapidly repaired if damaged. Precipitating (cathodic) inhibitors are simply chemicals which form insoluble precipitates that can coat and protect the surface. Precipitated films are not as tenacious as passive films and take longer to repair after a system upset.

Scaling Problems Factors

Typical scales that occur in cooling water systems are:

1. Calcium carbonate scale - Results primarily from localized heating of water containing calcium bicarbonate. Calcium carbonate scale formation can be controlled by pH adjustment and is frequently coupled with the judicious use of scale inhibiting chemicals.

2. Calcium sulfate scale - Usually forms as gypsum is more than 100 times as soluble as calcium carbonate at normal cooling water temperatures. It can usually be avoided by appropriate blowdown rates or chemical treatment.

3. Calcium and magnesium silicate scale - Both can form in cooling water systems. This scale formation can normally be avoided by limiting calcium, magnesium, and silica concentrations through chemical treatment or blowdown.

4. Calcium phosphate scale - Results from a reaction between calcium salts and orthophosphate, which may be introduced into the system via inadequately treated wastewater or inadvertent reversion of polyphosphate inhibitors present in recycled water.

The most common type of scaling is formed by carbonates and bicarbonates of calcium and magnesium, as well as iron salts in water. Calcium dominates in fresh water while magnesium dominates in seawater.

Control Scale can be controlled or eliminated by application of one or more proven techniques: 1. Water softening equipment Water softener, dealkalizer, ion exchange to remove scale forming minerals from make up water.

2. Adjusting pH to lower values - Scale forming potential is minimized in acidic environment i.e. lower pH.

3. Controlling cycles of concentration - Limit the concentration of scale forming minerals by controlling cycles of concentration. This is achieved by intermittent or continuous blowdown process, where a part of water is purposely drained off to prevent minerals built up.

4. Chemical dosage - Apply scale inhibitors and conditioners in circulating water. 5. Physical water treatment methods Filtration, magnetic and de-scaling devices

Control of scale with pH adjustment by acid addition is a simple and cost effective way to reduce the scaling potential. It functions via chemical conversion of the scale forming materials to more soluble forms - calcium carbonate is converted to calcium sulfate (using sulfuric acid), a material several times more soluble. Sulfuric acid (H2SO4) and hydrochloric acid (HCl) are the most common additives used for controlling the formation of calcium carbonate scale. The reaction of the acid with calcium bicarbonate is: H2SO4 + Ca (HCO3)2 = CaSO4 + 2H2O + 2CO2 2HCl + Ca (HCO3)2 = CaCl2 + 2H2O + 2CO2

Microbiological Growth Problems

Possible types of micro-organisms that exist in cooling water Micro-organisms Algae

Impact on cooling tower system

Provide a nutrient source for bacterial growth Deposit on surface contributes to localized corrosion process Loosened deposits can block and foul pipe work and other heat exchange surfaces

Fungi Proliferate to high number and foul heat exchanger surfaces

Bacteria Some types of pathogenic bacteria such as Legionella may cause health hazards Sulphate reducing bacteria can reduce sulphate to corrosive hydrogen sulphide Cathodic depolarization by removal of hydrogen from the cathodic portion of corrosion cell

Bacteria - A wide variety of bacteria can colonize cooling systems. Spherical, rod-shaped, spiral, and filamentous forms are common. Some produce spores to survive adverse environmental conditions such as dry periods or high temperatures. Both aerobic bacteria

(which thrive in oxygenated waters) and anaerobic bacteria (which are inhibited or killed by oxygen) can be found in cooling systems.

Fungi - Two forms of fungi commonly encountered are molds (filamentous forms) and yeasts (unicellular forms). Molds can be quite troublesome, causing white rot or brown rot of the cooling tower wood, depending on whether they are cellulolytic (attack cellulose) or lignin degrading. Yeasts are also cellulolytic. They can produce slime in abundant amounts and preferentially colonize wood surfaces.

Algae - Algae are photosynthetic organisms. Green and blue-green algae are very common in cooling systems. Various types of algae can be responsible for green growths which block screens and distribution decks. Severe algae fouling can ultimately lead to unbalanced water flow and reduced cooling tower efficiency. Diatoms (algae enclosed by a silicaceous cell wall) may also be present but generally do not play a significant role in cooling system problems.

Treatment Methods Chemical biocides are the most common products to control the growth of micro-organisms. Three general classes of chemicals are used in microbial control.

1) Oxidizing biocides 2) Non-oxidizing biocides 3) Bio-dispersants.

Oxidizing Biocide Oxidizing biocides are powerful chemical oxidants, which kill virtually all micro-organisms, including bacteria, algae, fungi and yeasts. Common oxidizers are chlorine, chlorine dioxide, and bromine, ozone, and organo-chlorine slow release compounds. Ozone is now days widely used to curb microbial growth. The most effective use of oxidizing biocides is to maintain a
constant level of residual in the system. Oxidizing biocides are usually maintained at a continuous level in the system.

Since oxidizing biocide may sometimes be corrosive, corrosion inhibitors shall be added and selected to ensure compatibility.

Non-oxidizing Biocide Non-oxidizing biocides are organic compounds, which kill micro-organism by targeting specific element of the cell structure or its metabolic or reproductive process. Non-oxidizing biocides are not consumed as fast as the oxidizing types and remain in the system for a significant period of time until they pass out with the blowdown. They often have the added advantage of breaking down into harmless, nontoxic chemicals after accomplishing their bacteria-killing purpose. They are effective where chlorine may not be adequate.

Chlorine Chlorine is the most widely adopted biocide for large circulating water systems. It provides a residual biocide in the treated water and can be readily checked. Its effectiveness increases when it is used with other non-oxidizing biocides and biological dispersants. Chlorine can be dosed in the form of sodium hypochlorite. A mixture of hypochlorous acid (HOCl), hypochlorite ion (OCl), and chloride ion (Cl) is formed when hypochlorite is added to water.

COOLING WATER TREATMENT IN F&N DAIRIES PRODUCT NAME NAME OF CHEMICAL (ACTIVE INGREDIENT) DIANODIC DN 2101 NICLON 70T CORRSHIELD NT 4201 SPECTRUS NX 1100 GENGARD GN 7002 CWT 3366 CWT 3050 CWT 3060 Potassium Hydroxide Calcium Hypochlorite Sodium Hydroxide Biocide Polymer Solution Phosphate Organic amines Halogen oxidizer

DIANODIC DN 2101

It is a corrosion inhibitor. It is an aqueous alkaline solution of inorganic salt, phosphonate, polymer and organic heterocyclic compound. Used in non-chromate cooling water treatment technology. It is a two component treatment program featuring a truly effective calcium phosphate inhibitor that permits higher phosphate concentrations necessary for proper mild steel corrosion protection.

The first component is the corrosion inhibitor-a blend of orthophosphate and polyphosphate for ferrous metal protection, phosphonate for calcium carbonate prevention and a copper corrosion inhibitor. The second component is the calcium orthophosphate inhibitor/dispersant.

NICLON 70T

Used for disinfection purpose. It is calcium hypochlorite granular. Disinfection and sanitization are achieved by dissolving calcium hypochlorite in water to produce a chlorine solution. Several grades, known collectively as Niclon-70, are typically used for sterilizing

and disinfecting swimming pools and drinking water, and is also used in sewage treatment systems.

CORRSHIELD NT 4201 It is a corrosion inhibitor. It is an aqueous alkaline solution of inorganic salts. CorrShield NT4201 cooling water treatment provides superior corrosion inhibition to multi-metal systems operating at high or low temperatures. It is normally used for diesel and other internal combustion engines, hot water heating systems, chilled water circuits and other closed systems containing ferrous and non-ferrous metals.

SPECTRUS NX 1100 Spectrus NX1100 is a proprietary blend of antimicrobial agents, specifically formulated for industrial water applications. It may be used in open or closed recirculating cooling water systems. Spectrus NX1100 is also approved for use in auxiliary water systems as well as wastewater and waste material disposal applications. Spectrus NX1100 is water-based to minimize impact on the environment. It contains no metal-based stabilizers, such as copper or iron.

Spectrus NX1100 has been formulated in a waterbased solvent system, eliminating BOD and COD associated with solvents, such as glycol and oils. A water-based formulation is also safer to store and handle than a solvent-based formulation.

GENGARD GN 7002

It is a deposit control agent. It is used for most advanced and effective water treatment technology for open re-circulating cooling systems. It can be applied across the entire pH spectrum from neutral to alkaline and ensure. GenGard GN7000 series of products are designed for cooling systems operating in the near neutral pH 6.8 - 7.8 range. They utilize high levels of inorganic phosphate to promote the formation of a thin, protective iron oxide film on steel surfaces. This protective oxide film is extremely tenacious and does not interfere with heat transfer.

CWT 3366

It is a blend of stabilized phosphate and deposit control agents for use in closed-loop or hot water circuit system.

CWT 3050

It consists of organic amines and contains no free metal ions. It aids in the control of bacteria, fungi, algae and slimes in evaporative condensers, heat exchange water system and industrial cooling towers.

CWT 3060

It is a liquid halogen oxidizer aids in the control of bacterial, fungal and algae slimes in cooling water systems. It contains a blend of halogen based compound and penetrants for effective control of biofilms.

WASTE WATER TREATMENT PLANT The treatment system involve chemical treatment system, biological treatment system and dewatering system to comply with the Environmental Quality (Industrial Effluents) Regulations, 2009 under Fifth Schedule and COD discharge standard for industrial effluent under [Seventh schedule, Regulation 12] of Standard B. Design Criteria

Type of wastewater : Dairy & Beverage Wastewater Operation hours : 24 hours per day Mode of Operation : Continuous Peak flow : 150 m3/hr (every 100 hours) Peak flow duration : 2 hours consecutively Flow Temperature : 450C Design Parameters Capacity : 1200 m3/day @ 50 m3/hr BOD : 3000 mg/L COD : 5000 mg/L FOG : 500 mg/L TSS : 1000 mg/L pH : 4-11

Performance Final Discharge Effluent (Treated Water) The proposed wastewater treatment system shall comply with the Environmental Quality (Industrial Effluents) Regulations, 2009 under Fifth Schedule and COD discharge standard for industrial effluent under [Seventh schedule, Regulation 12] of Standard B. The important parameters are included: COD < 200 ppm max BOD < 50 ppm max TSS < 100 ppm max O&G < 10 ppm max

There must be no significant levels of substances known to be inhibitory to activated sludge treatment processes present in the effluent. pH must be adjusted to an average value of 6.5 7.5 prior to the biological treatment.

FLOW DIAGRAM

PROCESS DESCRIPTION

RAW PUMPING SYSTEM Bar Screen Chamber & Oil Trap Collection Pit The bar screen functions to screen out large objects. However, its primary function is to remove any coarse object that could clog the equipment and pumps. The bar screen installed has a gap size of 2mm. The oil trap removes all grease and oil that float on top of the wastewater. The denser wastewater flows toward the equalization tank.

Bar Screen

Oil Trap Collection

FLOW EQUALIZATION SYSTEM Equalization Tank 1 and Equalization Tank 2 The wastewater at the collection pit then proceeds to the equalization tanks. The equalization tank reduces the surge of organic load to the system and controls the fluctuations in wastewater characteristics and flow rate. The equalization tank also functions to provide continuous feed to the biological system even when there is no production. Equalization Tank 2 (EQ-2) has a total effective volume of 500m3 with a hydraulic retention time of 3.5 hours at peak flows of 150m3 /hr. Equalization Tank 1(EQ-1) has an effective volume of 80m3 and EQ-2 has an effective volume of 520m3. A silicon membrane diffuser with retrievable air distribution is installed to provide air. The air is used to mix the wastewater and prevent it from being in septic condition.

Equalization Tanks

NEUTRALIZATION AND CHEMICAL TREATMENT SYSTEM Reaction Tank

The wastewater is then pumped into the reaction tank. Alkaline (Caustic Soda) is added into the tank via the dosing pump. This will ensure the waste water is at a pH of 6.5-8.5. The pH had to be at this standard so that coagulation and flocculation can occur at its optimum efficiency. Then, in order to encourage the coagulation and flocculation process, coagulant is dosed from the coagulant dosing pump. Finally, A-polymer is dosed in the Reaction Tank. The chemical and wastewater is mixed thoroughly with an agitator.

Reaction Tank

Dissolved Air Floatation System (DAF) DAF separates suspended solids, oil, grease and other low density solids hence lowering the COD to the biological system. The maximum handling capacity is 72 m3/hr. Pressurized wastewater is released to atmospheric pressure and introduced into the system. This causes fine gas bubbles to be released from the solution. The mixture of air and solid then rises to the surface and is skimmed off. Sediment scum and floated sludge will then be discharged to the sludge holding tank. The clarifies water then flows from the bottom and enters the UASB distribution tank.

DAF Tank

BIOLOGICAL TREATMENT Upflow Anaerobic Sludge Bed The clarified water then goes into the UASB distribution tank. The pH of this tank is monitored and should be maintained at pH 7.0-8.5. From the UASB distribution tank, the wastewater then enters UASB1 and UASB2. The aim of the UASB reactors is to at least reduce the BOD and COD to a value of 70% or higher. The waste water enters the reactor from the bottom. The waste water then passes through an anaerobic sludge bed. At the anaerobic sludge bed, microorganisms react with the wastewater substrates. Then, at the top of the reactor, the water phase is separated from sludge solids and gas phase. The clarified water flows through a overflow view and proceeds to aerobic system. One important parameter is the pH of these two tanks at the bottom. It should be maintained at a pH of 7.0-8.5. This is to avoid the deactivation of the anaerobic bacteria. Finally, the anaerobic process releases biogas which is collected and sent to an enclosed flare system.

UASB Tank

Flare System

BIOLOGICAL TREATMENT AEROBIC SYSTEM Alternative Intermittent Cyclic Reactor (AICAR) The clarified water from the UASB reactor then goes to the AICAR distribution tank which acts as a holding tank before distributing it to the AICAR reactors. Each AICAR has two sub-reactors. They operate by alternately feeding and discharging wastewater. The AICAR system is equipped with blowers to provide aeration. This will ensure there is a continuous supply of oxygen. Each AICAR operates for three cycles a day at a duration of 4 hours each. After settling, the treated water is discharged and is the final discharge point.

AICAR

AICAR Operation

AICAR during aeration

AICAR during settling

AICAR Protocol

DEWATERING SYSTEM Drum Thickener The sludge from the AICAR system is transferred to the mixing tank before entering the drum thickener. The mixing tank uses a centrifugal screen to separate flocculated solids from the water. C-polymer is added into the mixing tank as flocculants to agglomerate the sludge.

Drum Thickener

Sludge Holding Tank (SHT) All the sludge from DAF, UASB reactor and drum thickener (from AICAR tank) is collected here with an effective volume of 140m3 with retention time of 2 days. Air is supplied to the SHT for mixing to prevent the tank to be in septic condition.

SHT Tank

Conditioning Tank The sludge is then transferred to the conditioning tank. Cationic polymer is added and mixed by the air diffuser to condition the sludge before moving to the Filter Press.

Conditioning Tank

Automatic Moving Cloth Membrane Filter Press This equipment functions to covert the sludge into solid sludge cakes that is disposed off accordingly.

Filter Press

ANAEROBIC TREATMENT Anaerobes flourish in the complete absence of dissolved oxygen. They use oxygen in the combined state as in nitrate and sulphate

Biogas (= methane + carbon dioxide) is a product of anaerobiosis whereas aerobic processes produce no biogas. Anaerobic treatment is relatively cheap because of its i. Low operating costs. ii. Less sludge production iii. Low space requirements. iv. High biogas production

Principles of anaerobic wastewater treatment Anaerobic wastewater treatment is the biological treatment without the use of air or elemental oxygen. Many groups of anaerobic bacteria work together in the absence of oxygen to degrade complex organic pollutants into methane and carbon dioxide (biogas). Their microbiology is more complex and delicate. In aerobiosis aerobes work individually to decompose organic matter. Anaerobiosis involves a number of chain reactions each being performed by a specific and specialized bacteria. Hydrolysis (conversion of solids into liquids), Acidogenesis (acid production) Acetogenic (acetate building) and Methanogenic (methane formation) phases are most common. Methane bacteria use acetic acid, (H2) & (CO2) to generate (CH4).

Advantages of Anaerobic Treatment Processes Less energy required: Anaerobic process requires less energy compared to aerobic process. Less biological sludge production: As it involves less energy less biomass production occurs requiring less volume for storage. Fewer nutrients required: Aerobic process needs more nutrients (as N, P, K) to treat industrial wastes. Their quantity is much less for anaerobic processes because less biomass is produced. Higher volumetric loadings: Aerobic processes are designed for an organic loading of 0.5 to 3.5 kg COD/cu.m.d whereas it is 3.5 to 35 kg COD/m3.d for anaerobic processes.

Disadvantages of Anaerobic Treatment Processes Anaerobiosis is relatively a slow process compared to aerobiosis. Anaerobes are more sensitive to toxic compounds than aerobes. The products of biological decomposition are more odourous, corrosive and less stable. Anaerobiosis operates in a narrow pH range and can not tolerate higher acidity (even that induced because of CO2 production) Need for alkalinity addition: The most significant negative factor that can affect the economics of anaerobic verses aerobic treatment is need to add alkalinity.

Anaerobic suspended growth process When no media exists within the reactor for the microbes to settle but are carried along with the wastewater flow (i.e. when the microbes are in suspended state within the wastewater) it is called Suspended Growth Processes. Three types of anaerobic suspended growth treatment processes are: i. The complete mix suspended growth anaerobic digester ii. The anaerobic contact process and iii. The anaerobic sequencing batch reactor Complete mix process: In this process the contents of the tank are intimately mixed so that fresh incoming wastewater gets intimately mixed with the old wastewater undergoing decomposition so that a homogeneous mix is obtained. For the complete mix anaerobic digester, the hydraulic(detention) retention and solids retention time (SRT) are equal. The retention time may be from 15 to 30 days depending on temperature and nature of wastewater. The complete mix digester without sludge recycle is more suitable for concentrated wastes with high concentrations of organic solids. Here no chance exists for the sludge to get separated from the wastewater as the contents are intimately mixed and no stratification can take place.

(ii) Anaerobic contact process: The anaerobic contact process overcomes the disadvantages of a complete mix process without recycle. Biomass is separated and returned to the complete mix or contact reactor so that the process SRT is longer than hydraulic retention time, therefore the anaerobic reactor volume can be reduced.

Chemical Used for WWTP in F&N DAIRIES

PRODUCT NAME POLYMER HI-FLOC A 601 POLYMER CATIONIC (HC) COAGULANT 80 CAUSTIC SODA FOAMTROL AF1440 NITRIC ACID

NAME OF CHEMICAL (ACTIVE INGREDIENT) Anionic polymer Cationic polymer Polyaluminium chloride Sodium hydroxide Petroleum distillates Nitric acid

POLYMER HI-FLOC A 601

Polymer Hi-Floc A 601 is a type of flocculent. It is a type of anionic polyacrylamide powder. It is used for clarification, filtration, air floatation, sedimentation, colour removal, sludge thickening and sludge dewatering.

COAGULANT 80 Polyaluminium chlorides are synthetic polymers dissolved in water. They react to form insoluble aluminium poly-hydroxides which precipitate in big volumetric flocs. The flocs absorb suspended pollutants in the water which are precipitated with the PAC and can together be easily removed. PAC can be used as a flocculant for all types of water treatment treatment, drinking water, industrial waste water, urban waste water and in the paper industry. The possible slightly higher unit price of PAC is compensated by a

lower dosage requirement no requirement for any neutralising agent (soda, lime) shorter flocculation time smaller amount of sludge reduced number of back washing steps higher quality of the treated water.

CAUSTIC SODA

It is composed of sodium hydroxide. Sodium hydroxide is utilized to raise the pH of water. It is an inorganic compound with the chemical formula NaOH. It is a white solid and highly caustic metallic base and alkali salt which is available in pellets, flakes, granules, and as prepared solutions at a number of different concentrations. Sodium hydroxide forms an approximately 50% (by weight) saturated solution with water. FOAMTROL AF 1440

It is composed of petroleum distillates. Used to control and remove foam from waste water.