Conceptual Design For Leachate Treatment Plant (LTP)

EMISSION REDUCTION IN
CITIES (ERiC) PROGRAMME

SOLID WASTE MANAGEMENT
DOCUMENT NO. IN SIDOARJO REGENCY DATE REV
PP-ERiCSDA-ED-001-XI-2018 3 Desember 2018 00
DOCUMENT TITLE:
CONCEPTUAL DESIGN FOR LEACHATE TREATMENT

PLANT (LTP)
BILL OF QUANTITY NUMBER : 5.1.1 Working Design of Treatment Step 2 and

leachate storage pond
RESUBMISSION CODE :
NEXT SUBMISSION CODE :
REVIEW DATE :
IFA : ISSUED FOR APPROVAL

AFD : APPROVED FOR DESIGN
AFC : APPROVED FOR CONSTRUCTION
00 23 Nov 2018 EF DA FA
REV DATE ISSUED PREPARED CHECKED APPROVED
Approval or review hereunder shall not be construed to relive Vendor/Subcontractor of his
responsibilities and liability under the contract
1
TABLE OF CONTENTS
1. GENERAL 1
2. PROCESS DESCRIPTION 2
3. LTP CONCEPT 3
4. EQUIPMENT 10
5. OPERATIONAL AND MAINTANANCE 14
2
LIST OF FIGURES
Figure 1 LTP Location Layouts 1
Figure 2 LTP Flow Diagram 2
Figure 3 Leachate Treatment Plant layout 6

Figure 4 Step 2 Flow Diagram 7
Figure 5 Nitrification Process Flow Diagram 8
Figure 6 Scheme of Step 2 8
3
LIST OF TABLES
Table 1 Leachate Characteristic 2
Table 2 Rainfall data 4

Table 3 Calculation of leachate storage capacity for Sidoarjo city 5
Table 4 Dimension of step 2 item 9

Table 5 Biology Process Equipment 12
Table 6 The cooling unit design data 12
Table 7 Main Equipment of Cooling system 13
Table 8 Excess Sludge Data 13
Table 9 Dewatering system main equipment 13
Table 10 UF main equipment 13
Table 11 The Chemicals Dosing systems 14
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DOCUMENT NO. DATE REV
1. GENERAL
Sidoarjo is one of the cities that belong to ERiC program. This program was related to municipal
solid waste management by constructing the sanitary landfill, sorting and composting plant. One of
the part of sanitary landfill is leachate treatment facility. This facility is important to eliminate
negative impact to environment such of 1. Emission of methane that gives contribution to green
house gas effect, and 2. leachate. Both product from sanitary landfill is from decomposition of
organic material under biological activity. Organic MSW (OMSW) on landfill deposit will
decomposed under anaerobic condition (absence of oxygen). First phase of decomposition process
is hydrolysis where organic solid waste will be formed into liquid phase. The liquid consistency will
be further decomposed into methane and release into atmosphere. That part will be released out from
landfill body by rain water intrusion. Leachate, therefore will contain high concentration of organic
material and nutrient.
Leachate with high organic and nutrient content will create a pollution in water body when releasing
without treatment. High organic and nutrient will take oxygen content in water body and cause a
death of fish and other destroy of life. Therefore, treatment of leachate prior to discharge to water
body is very important. The Eric Project Sidoarjo LTP layout is shown on figure below.
Figure 1 LTP Location Layouts

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2. PROCESS DESCRIPTION
2.1 LTP Process
• The first step consists of a pond for the anaerobic pre-treatment of the leachate
• The second step is an aerobic treatment with nitrification and denitrification
• The third step is an after-treatment of the leachate in constructed wetlands
2.2 Flow Diagram
Figure 2 LTP Flow Diagram
2.3 Leachate Caracteristic
The Leachate Characteristic was shown on table 1
Effluent
Influent (Maximum (after Effluent
Values) MBR) Requirements*
hourly (m3/h) 15.6
Hydraulic volume
daily (m3/d) 375
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annual (m3/a) 136875

COD (mg/l) 20000 ˂ 300 300
BOD5 (mg/l) 10000 ˂ 100 150
NH4 (mg/l) 2000 ˂5 Not mentioned
Total N (mg/l) Not given ˂ 60 60
TSS (mg/l) Not given ˂5 100
Ph - 6.0 - 8.0 6.0 - 8.0 6.0 - 9.0
Electric Conductivity µs/cm 20000 20000 Not mentioned
Table 1 Leachate Characteristic
3. LTP Concept
In principle, the real leachate treatment system based on elimination or concentration concepts.
Membran Bioreactor (MBR) is the technology that reaches maximum COD and nitrogen removal,
producing high quality-suspended solid-free effluent. MBR system has high elimination efficiency;
it is economically and environmentally sustainable for the treatment of landfill leachate.
3.1. Flow Diagram
MW Step 1 Step 2 Step 3 MW

1. LSP
3.2. Leachate Storage Pond Calculation

1. Leachate quantity
Leachate quantity is calculated based on formula that is issued from MoPWH;

𝑚3 𝑚
𝑄, = 0,6 𝑥 𝑅, 𝑥 𝐴, 𝑚2 𝑙𝑎𝑛𝑑𝑓𝑖𝑙𝑙 𝑎𝑟𝑒𝑎
𝑚𝑜𝑛𝑡ℎ 𝑚𝑜𝑛𝑡ℎ
Q = landfill flow
R = rainfall
A = space area of landfill
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2. Leachate Storage
Leachate storage is calculated based on reservoir routing formula :

𝑆𝑡𝑜𝑟𝑎𝑔𝑒 𝑣𝑜𝑙𝑢𝑚𝑒, 𝑚3 = ∆ 𝑚𝑎𝑥𝑖𝑚𝑢𝑚, 𝑚3 + ∆ 𝑚𝑖𝑛𝑖𝑚𝑢𝑚, 𝑚3
∆ 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑜𝑟 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 = ∑ 𝑄 𝑖𝑛𝑓𝑙𝑜𝑤, 𝑚3/𝑚𝑜𝑛𝑡ℎ ∑ 𝑄 𝑜𝑢𝑡𝑓𝑙𝑜𝑤, 𝑚3/𝑚𝑜𝑛𝑡ℎ
Basic calculation is base on rainfall maximum that is represented in year 2010, and one year
after that, in year 2011. Rainfall data is presented in table 2.
Table 2 Rainfall data
Average
Precipitation (mm/ month)
Month (mm/
month)
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014
Jan 205 377 146 256 405 294 259 386 282 63 267
Feb 292 886 517 209 653 353 295 303 324 62 389
Mar 318 288 314 250 120 174 379 285 361 77 257
Apr 256 263 191 136 148 312 230 42 117 69 176
May 283 227 21 22 360 170 226 31 213 49 160
June 176 0 30 4 110 68 2 85 218 47 74
July 121 0 40 0 1 105 15 0 13 15 31
Aug 5 0 0 0 0 80 0 0 0 0 9
Sept 15 0 0 0 0 48 0 0 0 0 6
Oct 53 0 8 49 0 258 0 7 0 0 38
Nov 80 31 79 205 27 95 214 66 143 0 94
Dec 392 248 209 372 171 282 0 298 0 0 197
Total 2196 2320 1555 1503 1995 2239 1620 1503 1671 382 1698
The result of storage capacity is presented in table 3.
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Table 3 Calculation of leachate storage capacity for Sidoarjo city

Inflow, Outflow, Cummulative Cummulative
Month m3/month m3/month inflow outflow different
Year 2010 max rainfall
1 10,795 11,625 10,795 11,625 -830

2 12,880 10,500 23,675 22,125 1,550
3 6,554 11,625 30,229 33,750 -3,521
4 11,431 7,500 41,660 41,250 410
5 6,413 7,750 48,073 49,000 -927
6 2,808 3,750 50,881 52,750 -1,869
7 4,116 3,875 54,997 56,625 -1,628
8 3,232 3,875 58,229 60,500 -2,271
9 2,101 3,750 60,330 64,250 -3,920
10 9,523 3,875 69,853 68,125 1,728
11 3,762 3,750 73,615 71,875 1,740
12 10,371 11,625 83,986 83,500 486
83,986 83,500
230 229
Year 2,011
1 9,558 11,625 93,544 95,125 -1,581
2 10,830 7,000 104,375 102,125 2,250
3 13,799 7,750 118,173 109,875 8,298
4 8,533 6,000 126,707 115,875 10,832
5 8,392 3,875 135,099 119,750 15,349
6 476 3,750 135,574 123,500 12,074
7 935 3,875 136,509 127,375 9,134
8 419 3,875 136,928 131,250 5,678
9 405 3,750 137,333 135,000 2,333
10 419 3,875 137,751 138,875 -1,124
11 7,968 3,750 145,719 142,625 3,094
12 419 3,875 146,138 146,500 -362
62,151 63,000
170 173
Total 146,138 146,500 Volume of Leachate storage 19,268 m3
Average,
m3/d 200 201 13%
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Leachate flow from that presented table is 200 m3/d, and average pumped flow is 250 m3/d
(with eff pump 80 %)
Base on PTS leachate quantity is calculated to be 375 m3/d.
Number of influent pump : 2 unit @ 16 m3/h, 24 hours pumping period/day
The minimum volume of Leachate Storage is 19.268 m3
For design capacity is chosen 49 x 49,2 x 8m
The layout for Leachate Treatment Plant is presented in Figure below:
Figure 3 Leachate Treatment Plant layout
3.3. Anaerobic Pond
Anaerobic Pond is a pond with a laminar flow of effluent which causes microorganism activity. The
anaerobic pond function is not only able to reduce the levels of BOD and COD, but also to reduce
the amount of fecal coli found in leachates (Alfiandy, 2003). The volume of anaerobic pond that
used on this project is 7500 m3 include biofilter fixed bed type media with maximum leachate flow
375 m3/d.
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3.4. Aerobic Pond
Step 2 consists of the aerobic biological treatment with nitrification and denitrification. The total
removal of the nitrogen must take place before drainage of the leachate into the reed bed (constructed
wetland) treatment plant.
STEP 1 Denitrification Nitrification 1 Nitrification 2 Nitrification STEP 3
Sludge Dewatering
Cooling System
System
Figure 4. Step 2 Flow Diagram
Denitrification
The denitrification reactor nitrate (NO3) is transformed into elementary nitrogen (N2). The
elementary nitrogen is non-toxic and simply leaves the system as gas. Any Ammonia (NH4) which
may be present in the raw effluent will proceed unchanged to the nitrification reactor. The
denitrification bacteria need energy for the reduction of NO3 to N2. So, it make sense to lead the
raw effluent with all its organic compounds to the denitrification reactor first:
• Less organics are passed on the subsequent aerated reactor, where consequently less organic
material needs to be oxidized to CO2: less air required = lower energy costs
• The energy demand of the denitrifying bacteria can be either completely or at least partially
covered by the organic compounds in raw effluent. As consequence, none or less external
carbon source is required for the denitrification process = lower costs for chemicals
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Nitrification
The aerated bioreactor (= nitrification reactor) NH4 is oxidized to NO3 by the use of air. The
activated sludge contains a NO3 is then pumped back to denitrification, where Nitrate will be
reduced to N2.
N2, NO,
N2O
NH3 NO2 NO3 Water and

Leachate Reduksi nitrat Nitrosomonas Nitrobacter Reduksi nitrat Bioreactor
Figure 5 Nitrification Process Flow Diagram
Step 2 Flow Diagram
Figure 6 Scheme of Step 2

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In this step 2 we proposed the system of treatment with dimension area as follow:
No Area Dimension
1 Storage Tank 7x7m
2 Denitrification Tank 6x6x8m
3 Nitrification-1 12 x 12 m
4 Nitrification-2 12 x 12 m
5 UF Tank (Container) 12 x 2.5 m
6 Sludge Tank (Container) 10 x 4 m
7 Cooling Unit 10 x 4 m
8 Blower Room 6x4m
9 Control Room 6x4m
Table 4 Dimension of step 2 item
Explanation
1. Leachate from storage pond is pumped into the storage tank
2. From storage tanks, leachates are pumped into bag filter
• There is 2 leachate pump and bag filter, which is one pump and bag filter is stand by if
the other need maintanance
• To find out the condition of the filter, there is pressure transmitter
3. Leachate goes into denitrification: The denitrification reactor nitrate (NO3) is transformed
into elementary nitrogen (N2). The elementary nitrogen is non-toxic and simply leaves the
system as gas. Any Ammonia (NH4) which may be present in the raw effluent will proceed
unchanged to the nitrification reactor. The denitrification bacteria need energy for the
reduction of NO3 to N2.
4. Nitrification 1 :
• The result from denitrification leachate nitrate levels are reduced again by air (using a
blower), its circulated until TT, pH, O2, PI are met.
• Due to the blower the water will produce foam, to avoid the negative effects of foam
there is an antifoam working on it.
5. The previous cycle repeated on Nitrification 2
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6. From Nitrification 2 the leachate goes into chamber filter, the rejected will go to dewatered
sludge container and the other will go to cooling unit.
7. The leachate goes into the screw, in the screw there is a heat exchanger that have cooling
water flows in it to absorb the heat from the leachate. There will be temperature indication
for checking leachate temperature.
8. From the cooling unit, the leachate is going back into denitrification pond.
9. External Filtration Unit :
• The result from Nitrification 2 will be pumped by UF pump to UF loop, Permeate tank
and circulated into Wash Tank.
• Fresh water is flowed to Wash Tank so that the leachate will be cleaner
• From the permeate tank, the leachate will pumped (include flow control) into Step 3
10. There will be a control room for this STEP 2, so that the parameter of leachate that through
every treatment can be checked.
3.5. Constructed Wetland
Constructed wetland is a leachate treatment pond by absorbing leachate liquid on a land planted with
certain plants within the area 120.4 x 28.4m. The nitrate effluent from step 2 is reduced by plants
and water, so the leachate that coming out into the river has met the required criteria.
4. Equipment
4.1 Denitrification and Nitrification
The biology will be a BIOMEMBRAT®-type MBR consisting of:
• a pre-denitrification (=upfront to the nitrification) where up to 90 % of the NO3-N will be

removed under optimal usage of BOD5 in the inlet = minimal usage of carbon source
• aeration basin (Nitrification), where COD, BOD5 and NH4-N are removed under optimized
oxygen uptake
• ultrafiltration for separation of biomass from treated effluent
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A MBR achieves the maximal possible COD reduction of all biological effluent treatment systems;
at the same time, an MBR removes reliably all of the BOD5 (>99 %) and all of the NH4 (>99 %)
4.2 UF Cross Flow MBR
Ultrafiltration (side-stream cross-flow type)
The ultrafiltration of a BIOMEMBRAT®-type MBR uses external mem-

branes and is placed on skids beside the reactors.
This has the decisive advantages of
- having a very small footprint
- being easily extendable & upgradable
- service and maintenance are very easy
4.3 Chamber screw press for sludge dewatering
The bacterial mass in the bioreactors multiply and grow and thereby constitute the so-called surplus
sludge. Thus the sludge in the bioreactors thickens over the time, a fact which has a negative impact
on both aeration and filtration properties. Therefore, surplus sludge needs to be removed from the
bioreactors on a regular basis.
The sludge is drawn from the recirculation pipe after the ultrafiltration because the UF has already
pre-thickened the sludge. It is let to the chamber screw press where the sludge is dewatered. The
centrate is led back to the bioreactors. The dewatered sludge has a much reduced volume and can
be discharged at far lower costs
4.4 Pre-Treatment
Theese were the pre treatment equipment consist of
4.4.1 Biology
Main Equipment
2 Feed pumps (1 duty + 1 reserve), 15.6 m³/h, stainless steel, eccentric pump
2 Basket strainers, 200 – 300 µm
2 Jet aeration systems 2,500 Nm³/h each, PP
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3 Blowers (2 duty + 1 reserve), 2,500 Nm³/h each, 850 mbar

2 Jet pumps (duty), 575 m³/h, stainless steel
1 Nitrate recirculation pump (duty), 270 m³/h, stainless steel
Main Equipment
1 Denitrification tank, either stainless steel or glass coated steel or coated concrete or eq.
with roof, ladder, platform, without insulation
~ 250 m³ usable volume
Height: 9m
Water table: 8m
2 Nitrification tanks, either stainless steel or glass coated steel or coated concrete or eq.
with roof, ladder, platform, without insulation
~ 1000 m³ usable volume per reactor
Height: 9m
Water table: 8m
Table 5 Biology Process Equipment
4.4.2. Cooling system

Design Data for the cooling system
Feed to biology [°C] 30
[m³/d] 375
Average ambient air temperature summer [°C] 35
Required temperature outlet MBR [°C] ≤ 38
Table 6 The cooling unit design data
Main Equipment of the cooling system
Heat exchanger 900 kW, stainless steel
Sludge pump / feed pump heat exchanger, 260 m³/h, stainless steel
Main Equipment of the cooling system
Cooling tower 900 kW, plastic
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Water pump cooling tower, 260 m³/h, stainless steel
Table 7 Main Equipment of Cooling sytem

4.4.3 Dewatering system
Excess sludge
Excess sludge per day [kgTS/d] ~1,470
TSS of excess sludge [kg/m³] 10 - 15
Excess sludge volume per day (TSS ~ 1,5%) [m³/d] ~103 - 107
Table 8 Excess Sludge Data
Main Equipment of the dewatering system

Chamber Filter, 13 m³/h
Feed pump, 13 m³/h, stainless steel, eccentric pump
Filtrate pump, 12 m³/h, stainless steel, eccentric pump
Sludge conveyor
Polymer dosing station
Table 9 Dewatering system main equipment
Main Equipment for UF

1 UF Circulation pump, 250 m³/h, stainless steel
1 UF Loop (6 modules, 0 dummy, bends, connecting pieces, clamps, accessories)
1 UF Wash pump, 110 m³/h, stainless steel
1 UF Wash tank, 2 m³, PE
1 Permeate pump, 18 m³/h, stainless steel
1 Permeate tank, 2 m³, PE
Table 10 UF main equipment
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4.4.4 Chemical Requirements & Dosing Systems
Dosing systems for the following chemicals
☒ Anti-foaming agent (Chemical delivered and stored in drums)
Biological treatment systems may occasionally foam, thus the dosing of antifoaming
agent can be desirable or even required.
☒ Caustic: 50 % NaOH
☒ IBC or tank
Depending on the pH of the effluent and on the effluents characteristics, the dosing of
caustic soda may be required in order to keep the pH stable. This is necessary for a stable
and effective operation of the biology.
☒ Drum pumps for cleaning agents for CIP cleaning (Chemicals delivered and stored in
drums)
The membrane CIP (cleaning-in-place) design includes for both an alkali and acid
wash, which typically will take place once every 6-8 weeks for the UF. After the cleaning,
the CIP solution - typically made at 0.5 % to 1% - can be discharged back to the
bioreactor.
Table 11 The Chemicals Dosing systems
5. Operational and Maintanance
Aeration system in the MBR

In order to achieve excellent treatment, the oxygen supply of the biomass has to be optimal.
The oxygen must be inserted into the wastewater in form of air by means of blowers and an ejector
system which is very effective at aerating, dispersing and mixing the biomass at the same time. The
ejector system works on the principle of a vacuum pump and requires a jet pump installed outside
the tank. This ejector-aeration system maximizes the oxygen uptake in the system. Thereby air
(=power) consumption can be reduced. The ejector itself has no moving part and therefore requires
no mainatanace. One blower is necessary for the regular operation of the plant while often a second
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IN SIDOARJO REGENCY
blower is installed on stand-by in order to always secure oxygen input into the biology. This also
enables the system to enhance oxygen input in times of especially high COD loads.
Ultrafiltration
The ultrafiltration operation is based on a side-stream crossflow membrane filtrtation process using
true UF tubular membrane modules.
The mixture of activated sludge and effluent is pumped from the bioreactor through the tubular
membranes in order to separate the treated waste water from the activated sludge. The tubular
membrane modules provide the complete retention of activated sludge, meaning all bacteria,
suspended solids, macro-molecules and colloidal matter are safely retained within the system and
are continuously returned to the bioreactor for more biological treatment.
The tubular membrane modules allow the operation at much higher concetration of activated sludge
in bioreactor compared to the submerged disk modules. This can provide major cost saving and
reduced volume of the waste sludge to dewater.
A typical basic UF- unit consist of 2 – 6 tubular membrane modules connected to series to form a
UF-loop. Each UF-loop has a dedicated circulation pump, sized to provide the required crossflow
velocity along the membrane surface the optimal means to reduce fouling and maintain a high
permeate flux.
Because of its high cross-flow velocity, the UF system needs little cleaning compared to other
membrane system. Yet occasionally the UF membrane modules will need to be rinsed or cleaned.
This can be easily achieved via the wash pump by using water or permeate stored in the wash tank.
The rinse and cleaning procedure are automated and require only minimum attention. The UF-loop
can be rinsed or cleaned individually while remaining loops are in operation.
15

Conceptual Design For Leachate Treatment Plant (LTP)

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Conceptual Design For Leachate Treatment Plant (LTP)

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EMISSION REDUCTION IN

CITIES (ERiC) PROGRAMME

CONCEPTUAL DESIGN FOR LEACHATE TREATMENT

BILL OF QUANTITY NUMBER : 5.1.1 Working Design of Treatment Step 2 and

NEXT SUBMISSION CODE :

IFA : ISSUED FOR APPROVAL

Figure 1 LTP Location Layouts 1

Figure 2 LTP Flow Diagram 2

Figure 3 Leachate Treatment Plant layout 6

Table 1 Leachate Characteristic 2

Table 2 Rainfall data 4

Table 4 Dimension of step 2 item 9

Figure 1 LTP Location Layouts

2.1 LTP Process

2.2 Flow Diagram

Figure 2 LTP Flow Diagram

2.3 Leachate Caracteristic

The Leachate Characteristic was shown on table 1

annual (m3/a) 136875

3.1. Flow Diagram

MW Step 1 Step 2 Step 3 MW

3.2. Leachate Storage Pond Calculation

Leachate quantity is calculated based on formula that is issued from MoPWH;

Leachate storage is calculated based on reservoir routing formula :

∆ 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑜𝑟 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 = ∑ 𝑄 𝑖𝑛𝑓𝑙𝑜𝑤, 𝑚3/𝑚𝑜𝑛𝑡ℎ ∑ 𝑄 𝑜𝑢𝑡𝑓𝑙𝑜𝑤, 𝑚3/𝑚𝑜𝑛𝑡ℎ

Table 2 Rainfall data

Table 3 Calculation of leachate storage capacity for Sidoarjo city

1 10,795 11,625 10,795 11,625 -830

Figure 3 Leachate Treatment Plant layout

3.3. Anaerobic Pond

3.4. Aerobic Pond

STEP 1 Denitrification Nitrification 1 Nitrification 2 Nitrification STEP 3

Figure 4. Step 2 Flow Diagram

NH3 NO2 NO3 Water and

Figure 5 Nitrification Process Flow Diagram

Step 2 Flow Diagram

Figure 6 Scheme of Step 2

3.5. Constructed Wetland

4.1 Denitrification and Nitrification

The biology will be a BIOMEMBRAT®-type MBR consisting of:

• a pre-denitrification (=upfront to the nitrification) where up to 90 % of the NO3-N will be

4.2 UF Cross Flow MBR

Ultrafiltration (side-stream cross-flow type)

The ultrafiltration of a BIOMEMBRAT®-type MBR uses external mem-

3 Blowers (2 duty + 1 reserve), 2,500 Nm³/h each, 850 mbar

Table 5 Biology Process Equipment

4.4.2. Cooling system

Table 6 The cooling unit design data

Main Equipment of the cooling system

Heat exchanger 900 kW, stainless steel

Cooling tower 900 kW, plastic

Water pump cooling tower, 260 m³/h, stainless steel

Table 7 Main Equipment of Cooling sytem

Table 8 Excess Sludge Data

Main Equipment of the dewatering system

Table 9 Dewatering system main equipment

Main Equipment for UF

Table 10 UF main equipment

4.4.4 Chemical Requirements & Dosing Systems

Dosing systems for the following chemicals

☒ Anti-foaming agent (Chemical delivered and stored in drums)

Table 11 The Chemicals Dosing systems

5. Operational and Maintanance