Water Treatment Plant Sludge

Volume Reduction Project

Team : xxxx
Dec 30, 2015

Content
1.
2.
3.
4.
5.
6.
7.

Background
Project Objective
Project Scope
Project Study & Data Collection
Project Cost Estimation
Return on Investment
Project Schedule

Current Project Progress

No

Content

Person In
Charge

Target
Completio
n Date

%
Completio
n

Background

By Oct 31,
15

100%

Project Objective

By Oct 31,
15

100%

Project Scope

By Oct 31,
15

100%

Project Study &

Data Collection

By Nov 30,
15

Project Cost
Estimation

By Dec 15,
15

Return on
Investment

By Dec 15,
15

Plan Project
Schedule

By Dec 15,
15

Remarks

1. Background
As part of company green vision to meet the Environmental
Objective other than the cost reduction and with
environmental responsibility at company core mission, the
company is looking into how to reduce the waste.

1. Background
Total disposal activated sludge record for past 3 years
Year

Weight
(MT)

Average
(MT/Day)

Disposal
Price/MT
(RM)

Total Price
(RM)

2012

160

0.438

2500

400,000

2013

158

0.4328

2500

395,000

2014

165

0.4520

2500

412,500

Activated Sludge generated from Waste Water Treatment is

0.4MT/Day, it will be collected and store in the sludge pit.
Once the sludge pit at 60% level, the activated sludge (AS) is
feed to sludge dewatering system (dehydrator) to remove water
from 90 wt% to 70 wt%.
The outlet sludge cake from dehydrator then will be kept in
metal drums, seal and labeled as SW204.
This sludge cake then will be sent out to Department Of
Environment (DOE) licensed contractor for disposal.
The quantity of sludge is high (0.4 MT/Day, 20 Drums/Day). Need
a lot of storage space and expensive disposal cost.
5

PIC : Please sketch this diagram

Flow Diagram For Sludge Dewatering System

6

2. Project Objectives

Objective of this study is to achieve :

Company Green Vision
Reduce the volume of activated sludge from WWT
Plant
To reduce disposal cost
To reduce storage space of activated sludge

3. Project Scope
To install a 0.6 t/day capacity Sludge Reduction System
which operates for 12 hrs per day.
Consist of few major equipments in the system which are:
1.Process chamber the chamber where ashing and
cracking take place
2.Bag Filters & Deodorizer for effective of removal
dust/particles and decompose of organic fumes
3.Wet scrubber for final polishing to effective control of
dust and fumes

PIC : Please sketch this diagram

4. Project Study Process Chamber

Process Chamber is a Mini Carbonizer
Carry out drying and ashing process
This process reduce moisture/weight/volume of
activated sludge by drying and carbonizing all
types of organic
Temperatures in a controlled and isolated
system at around 300C 450C

10

4. Project Study Bag Filter

Bag filter is an air pollution
control device that remove
particulates out of air or gas
released from the chamber.

Process:
- Gas/Air enter the baghouse through the hoppers.
- The gas is drawn through the bag filter, either on
the inside or the outside (depend on the cleaning
method) and the layer of dust accumulates on the
filter media surface until air cannot longer flow pass
through it (reach pressure drop limit).

11

4. Project Study Bag Filter

Filtration mechanism:
i. Inertial collection Dust particles strike the
filter media
ii. Interception Pore size of the filter
iii. Brownian movement Submicrometre
particles are diffused
iv. Electrostatic forces presence o an
electrostatic charge on the particle
A combination of these mechanisms result in
formation of dust cake on the filter media.

12

4. Project Study Bag Filter

01- Separation
chamber
02- Dust laden gas
inlet
03- Baffle plate
04- Rotary valve
05- Filter bags
06- Tube sheet (cell
plate)
07- Filter cage
08- Clean gas
chamber
09- Clean gas
outlet
10- Compressed air
tank
11- Diaphragm
valve
12- Blow pipe
13- Water trap
14- Sequential
13
controller

4. Project Study Deodorizer

Need someone to find info related to
Deodorizer, it is similar to incineration
deodorizer

14

3. Project Study Scrubber

Need someone to find info related to Wet
Scrubber, it is similar to incineration deodorizer

15

4. Data Collection - Activated Sludge Properties

Study
The activated sludge properties before and after
treatment by Pilot Process Chamber.
Description

Before

After

Type

Paste/semi
solid

Carbon/Char

Density (kg/m3)

0.85 ~ 1.1

>1

30~35
Unknown
65~70 %

>90 %
Unknown
<5 %

Composition (wt
%)
Organic solid
Inorganic solid
Moisture/Water

16

4. Project Study - Benefits

Weight Reduction : > 80.0%
Description

Before

After

Paste/semi
solid

Carbon/Char

1.12 Kg

0.19Kg

Paste/semi
solid

Carbon/Char

1.02 Kg

0.18Kg

Weight
Reduction (%)

1 st Sample
Characteristic
Weight (Kg)

83%

2nd Sample
Characteristic
Weight (Kg)

82%

3rd Sample
Characteristic
Carbon/Char
This
will reduce thePaste/semi
quantity of WWTPs
sludge volume and
solid the disposal cost
at the same time reduce
Weight (Kg)
Kg
0.21Kg
80%
Further
step is to do1.06
complete
Toxicity
Characteristics
Leached Procedure (TCLP) testing to get permission from
DOE for dispose at normal landfill
17

5. Project Cost Estimation

Estimated project cost : RM 775k
Main Equipment *

: RM 580k

Equipment packing (delivery & crane services)

15k

: RM

Engineering design services & DOE approval : RM 20k

Installation

: RM 45k

Piping

: RM 65k

Civil works

: RM 50k

Main Equipment : Process Chamber, Filter Bag System, Deoderizer and

Scrubber, water tank and a small chimney

18

6. Return on Investment
Description

Cost

Project payback period calculation assum

Project investment cost

(RM)

775,000

Average waste generation per month

Waste disposal cost per

year (RM)

400,000

Operating cost per year

(RM)
Fuel (NG)
Electricity
Water
Compressed dry air
Manpower

166,042
30,660
19,440
3,942
Negligible
No
additional
manpower
40,000
72,000

Maintenance service
Waste disposal
Cost saving per year
(RM)
Return on Investment
(yrs)

Waste disposal cost = RM 2,500/MT

Natural gas required = 120 SM3/day
Natural gas price = RM 0.70
Electricity required = 120 kWh/day
Electricity price = RM 0.45
Water required = 18m3/day
Water price = RM 0.60

233,958
3.3
19

7. Plan Project Schedule

2016

Durati
on
Apr May
(Week)

Items
Management
Approval
Detail design &
engineering
ITB & Procurement
Fabrication

Jul

Aug Sept Oct

Nov Dec

Jan

Feb

Mar

8
12

Field installation,
testing &
commissioning

Jun

2017

Total : 40 Weeks

20

THANK YOU