ENVIRONMENTAL ENGINEERING DESIGN 'WASTEWATER TREATMENT DESIGN REPORT OF TREATING 5 m 3 /hr PALM OIL MILL EFFLUENT (POME)' PDF

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UNIVERSITY KUALA LUMPUR MALAYSIAN INSTITUTE OF CHEMICAL AND BIO ENGINEERING TECHNOLOGY CEB 40003 ENVIRONMENTAL ENGINEERING DESIGN ‘WASTEWATER TREATMENT DESIGN REPORT OF TREATING 5 m3/hr PALM OIL MILL EFFLUENT (POME)’ Name Student ID Section MUHAMMAD SYAFIQ BIN ZAINOR DIN 55214117134 LO1 MUHAMMED AZR...

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UNIVERSITY KUALA LUMPUR MALAYSIAN INSTITUTE OF CHEMICAL AND BIO ENGINEERING TECHNOLOGY

CEB 40003 ENVIRONMENTAL ENGINEERING DESIGN

‘WASTEWATER TREATMENT DESIGN REPORT OF TREATING 5 m3/hr PALM OIL MILL EFFLUENT (POME)’

Name

Student ID

Section

MUHAMMAD SYAFIQ BIN ZAINOR DIN

55214117134

LO1

MUHAMMED AZRUL BIN GAZALI

55214117219

LO1

NUR FATIHAH BINTI SUKOR

55214117171

LO1

NURAEISYA HAKIM BOEY BINTI DANIAL HAKIM BOEY

55214117099

LO1

HALIMAHTON BINTI Ab GAPAR

55214117213

LO1

Table of Contents 1.0

Introduction ..................................................................................................................... 4

1.1

Background of Study.................................................................................................... 4

1.2

Problem Statement ...................................................................................................... 4

1.3

Objectives .................................................................................................................... 5

2.0

Palm Oil Mill Effluent (POME) .......................................................................................... 6

2.1

Characteristics of POME .............................................................................................. 6

2.2

Existing Treatment Method For POME......................................................................... 8

3.0

New Treatment Approach ................................................................................................ 9

3.1

Suggestion for POME Treatment Method .................................................................... 9

3.2

Process Description of Suggested Treatment .............................................................. 9

3.2.1

Bar Screening ....................................................................................................... 9

3.2.2

Grit Chamber .......................................................................................................10

3.2.3

Coagulation & Flocculation ..................................................................................10

3.2.4

Primary Clarifier (Sedimentation) .........................................................................11

3.2.5

Activated Sludge & Secondary Clarifier................................................................12

3.2.6

Disinfection (Chlorination & Dechlorination) .........................................................13

3.2.7

Anaerobic Sludge Treatment ...............................................................................14

3.2.8

Sludge Dewatering (Belt Filter Press) ..................................................................16

3.2.9

Advanced Treatment (Polymeric Ultrafiltration) ....................................................17

3.3

Suggested Location for POME Treatment Plant ..........................................................18

3.4

POME Wastewater Treatment Plant Drawing .............................................................19

4.0

Calculation for POME Treatment Plant ...........................................................................20

4.1

Grit Chamber ..............................................................................................................21

4.2

Coagulation & Flocculation .........................................................................................23

4.3

Primary Clarifier ..........................................................................................................25

4.4

Activated Sludge .........................................................................................................27

4.5

Advanced Treatment (Ultrafiltration) ...........................................................................33

4.6

Disinfection .................................................................................................................33

4.7

Anaerobic Digester .....................................................................................................34

4.8

Belt Filter Press ..........................................................................................................40

5.0 5.1

Equipment Cost ..............................................................................................................42 Preliminary Treatment: Bar Screen & Grit Chamber....................................................42 2

5.2

Primary Treatment: Coagulation & Flocculation and Primary Clarifier .........................42

5.3

Secondary Treatment: Activated Sludge & Secondary Clarifier ...................................45

5.4

Advanced Treatment: Ultrafiltration .............................................................................46

5.5

Disinfection: Chlorination & Dichlorination ...................................................................47

5.6

Sludge Management: Anaerobic Sludge Digester & Belt Filter Press ..........................48

6.0

Economy Analysis ..........................................................................................................49

6.1

Total Process Equipment Cost ....................................................................................50

6.2

Estimation of Fixed Capital Cost .................................................................................50

6.3

Maintenance and Operating Cost Estimation ..............................................................52

6.4

Operating Labor Cost ..................................................................................................52

6.5 Estimation of Selling Price for Treating POME Effluent Based on Treatment Plant Capacity ................................................................................................................................53 6.6 7.0

Estimation Return of Investment by Payback Calculation Method ...............................53 Safety Analysis ...............................................................................................................54

7.1

Safety for Equipment in Wastewater Treatment Plant .................................................54

7.2

Safety and Health in Palm Oil Mill Effluent Treatment plant. .......................................57

7.3

Introduction .................................................................................................................58

7.4

Injury Statistics............................................................................................................58

7.5

Who is affected ...........................................................................................................58

7.6

Plant Safety ................................................................................................................58

8.0

7.6.1

Chemical Storage ................................................................................................58

7.6.2

Transportation......................................................................................................58

7.6.3

Plant Location ......................................................................................................58

7.6.4

Equipment Safety ................................................................................................59

7.6.5

Worker Safety ......................................................................................................59

7.6.6

Personal Protective Clothing and Equipment (PPE) .............................................59

Discussion and Conclusion.............................................................................................62

REFERENCES .........................................................................................................................64

3

1.0

Introduction

1.1

Background of Study Palm oil mill effluent (POME) is a waste generated from fresh fruit brunch (FFB)

processes. Some of the companies discharge their effluent without treatment and this will affect our environment. Treating POME requires high cost, therefore the companies would prefer to discharge the POME directly into the river. Malaysia has been known as one of the world’s leading producers and exporters of palm oil products. When demand is increasing, the production and the capacity of fresh fruit brunch are increased, therefore it will affect the amount of POME that will be discharged. In 2012, Malaysia produced about 99.85 million ton of fresh fruit bunch per year. From the process, 5-5.57 tons of water needed to sterilize the palm fruit bunch and about 50% of water will returning to palm oil mill effluent process. From the record, 6 countries were involved in producing the palm oil such as Indonesia, Malaysia, Thailand, Nigeria, Columbia and others country. This shows that Malaysia and Indonesia are one of the main country that produces palm oil. Malaysia have many large plantation companies such as Sime Darby, IOI Corporation, Kuala Lumpur Kepong, Genting Plantation, Felda Global Ventures Holdings and United Plantations. The POME treatment in Malaysia, most of palm oil mils choose to adopt the ponding system for treating the POME. Four type of ponding system that are used in palm oil industry such as waste stabilization ponds, activated sludge system, closed anaerobic digester and land application system. One of the most significant components in the palm oil mill system is the wastewater treatment facility. This is because the plant is to treat effluent from palm oil mills effluent (POME), which is produced in massive quantity during crude palm oil (CPO) manufacturing. Effluent of the palm oil mill (POME) is essential to be treated to ensures the environment is protected. Four type of ponding system that are used in palm oil industry such as waste stabilization ponds, activated sludge system, closed anaerobic digester and land application system (Kamyab et al, 2018). 1.2

Problem Statement In global market, palm oil provides one of the leading vegetable accounting almost one-

quarter of global consumption 60% of international world trading are in vegetable oil. Total net of palm oil production has strongly increased by 128% equivalent to 58 million tons over the past decades due to global demands in oil consumption. Palm oil industries has been developing quickly and is ranked at fourth largest contributor in Malaysian’s national economy (Ferdous Alam, Er, & Begum, 2015). However, the number of palm oil mills increases as year past thus 4

contributing in the capacity of fresh fruit bunch waste or effluent discharge. In order to extract oil to produce 1 ton of crude palm oil required about 5-5.7 tons of water during processing which contributing up to 50% of the water turning into palm oil mill effluent (POME) (Paridah et al., 2016). Effluent water is defined as water discharged from manufacturing and/or production industry, which contain high level contaminants such as soluble compound that can pollute our environment. Such hazardous compound may exist in form of gas, liquid and/or liquid such as methane gas, Sulphur and nitrogen-based compound, ions in either organic or inorganic and all the contaminant’s concentration above the threshold amount. Since there are a lot of pollutant contains in palm oil mill effluent, it is necessary to treat or purified the effluent before discharging it to the environment. According to J. C. Igwe and C.C. Onyegbado (2000), untreated palm oil mill effluent contains high level of biological oxygen demand (BOD) in range between 25000 to 35000 mg/L (Igwe & Onyegbado, 2007). Thus, treating the palm oil effluent which can be the source of water pollution are the highest priorities in palm oil industry as according to the Federal Environmental Protection Agency (FEPA); Department of Petroleum Resources; World Health Organization (WHO); etc. Treating raw palm oil mill effluent is biggest challenge in palm oil industries due to its characteristic. Palm oil mill effluent usually has brownish colour instead of having high concentrations in suspended solids and organic compound potentially to disturb the balance of the environment. A lot of water is consumed for processing during milling stages, hence generating 43.29 million cubic waters per year towards raw palm oil mill effluent for an average of 2.5 m3 of palm oil mill effluent produced (Zainal, Jalani, Mamat, & Astimar, 2017). Due to high load of pollutants and its potential in violating the environment, Malaysian Department of Environmental reinforced the existing law towards the palm oil industries. Recently, government has reduced the BOD discharge limits from 100 mg/L to 50 mg/L and 20 mg/L according to the location of palm oil mill. This regulation will evolve sooner as the government are looking forward to environmental protection and sustainability. 1.3

Objectives



To design a palm oil mill effluent wastewater treatment plant



To treat the high-level contaminants contains in the palm oil mill effluent.



To comply with the standard discharge as stated in the rules and regulation of Environmental Quality Act 1974.

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2.0

Palm Oil Mill Effluent (POME)

2.1

Characteristics of POME Palm oil mill effluent (POME) is a type of wastewater produced during extraction process

in crude palm oil production. According to (Yacob et al., 2005), due to high demand of edible oil in Malaysia, it is estimated that an average of 30 million tons of POME were produced from 381 palm oil mills in Malaysia in 2004 and the number is expected to increase in future. POME is known as a non-toxic thick brownish colour of liquid waste with high viscosity and has unpleasant odor (Ibrahim et al., 2013), lower pH range and has fine suspended solid (A. Ahmad & Krimly, 2014). POME compositions are mainly consisting of (95%-96%) water, total solids (4%-5%, include 2% suspended solids) and (0.6%-0.7%) oil and grease (Abdullah & Sulaim, 2013). The physical appearance of raw or untreated POME is blackish brown colour due to the presence of fulvic acid components, humic acid and also tannin and lignin (Kongno et al., 2012) and normally has high range of temperature between (80ºC to 90ºC). The condition of POME is in acidic condition with pH value around 4.5 as it contains complex form of organic acids (Md Din et al., 2006). POME is considered as a non-toxic wastewater because there are no chemicals used during the extraction process (Ma et al., 1993). (Madaki & Lau Seng, 2013) stated that POME wastewater has high value of Biochemical Oxygen Demand (BOD) and Chemical Oxygen Demand (COD) and sometimes the number is thousand times greater than normal domestic wastewater. The characteristics of POME is may vary according to the discharge limit from the factory, climate and condition of the palm oil mill processing (Ahmad, Sumathi, & Hameed, 2006). Table 1 summarized the average characteristics of POME wastewater generated in Malaysia.

6

Table 2.1 Characteristics of POME (MPOB, 2004)

Based on Table 1, it can be deduced that even though POME is a non-toxic, discharging the POME wastewater with high amount of pollutants and organic matter could cause a significant environmental impact to the natural water body. So, proper treatment is needed in order to reduce the contaminant to the acceptable limit according to the standard discharge limit stated in Environmental Quality Act (EQA 1974). Table 2 showed the standard parameters discharge limit by Department of Environment (DOE). In this study, the proposed treatment design must be able to treat 5 m3 per hour flowrate of discharged POME from the palm oil mill. Table 2.2 Acceptable Discharge Limit for POME Wastewater (EQA, 1974)

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2.2

Existing Treatment Method For POME According to Ahmad & Krimly (2014) and Igwe & Onyegbado (2007), the common method

used in treatment plant for treating POME wastewater prior to discharge to environment is preliminary treatment and biological treatment (Secondary Treatment). Preliminary treatment was used to remove solid particles that can cause damage to the treatment plant while biological treatment including anaerobic (Anaerobic Digestion Tank) and aerobic (Aerated Lagoon) treatment was used to remove organic contaminants in the POME wastewater. This is because POME has high amount of organic contaminant in terms of COD and BOD. The flow of the treatment can be referred to Figure 1.

Figure 2.1 Typical Treatment Method for POME Treatment The Methane gas produced will be recovered as a source of energy while the sludge produced which is high nutrient will be used as a fertilizer. Even though, this method can remove the massive organic contaminant according to the standard, however, the quality of the effluent produced in this treatment process is very poor. Hence, in this study, conventional treatment method of wastewater is suggested to replace the common treatment process in order to enhance the quality of treated wastewater produced.

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3.0

New Treatment Approach

3.1

Suggestion for POME Treatment Method

The overall treatment flow of the suggested treatment method can be referred to Figure 1.

Figure 2.2 Overall Process for POME Treatment

3.2

Process Description of Suggested Treatment

3.2.1

Bar Screening May include fine and coarse screening, generally operated mechanically. Use ancillary

devices to intercept floating and suspended debris to remove screenings. Flush organic material exploits the sewage stream and compacts the final screening residue for off-site disposal. Usually place in series of closely bars across the flow with inclination between 30° and 60°

9

3.2.2

Grit Chamber Interception and separation of inorganic grit particles as well as grit washing and storage

facilities. Grit removal avoids its downstream build-up in process units and the possibility of excessive wear in pumps, sludge dewatering plants and other equipment. 3.2.3

Coagulation & Flocculation It is described as a process where coagulant agent such as alum providing positive charge

towards suspended solids particle and hence allow it to be attached together after charge neutralization. Once the negative charges are neutralized, the suspended solids form a small particulate called micro flocs but still invisible to our na...