JEDDAH INDUSTRIAL CITY

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1 JEDDAH INDUSTRIAL CITY WASTEWATER TREATMENT PLANT A Presentation by : Engr. Mowafaq Al-Sugeir Managing Director ICDOC SAWEA 2007 WORKSHOP, AL-KHOBER 4 December 2007

2 Built & Being Operated by : on Build-Operate-Transfer (BOT) Basis as the First Project in the Kingdom of Saudi Arabia

3 The Presentation will highlight: 1. History of the ICDOC & the Development of the Plant 2. Aims & Objectives of the Project 3. Factories Existing in the Area & Served by Connections 4. Layout & Process Flow Diagram of the New Plant 5. Details of the Unit Processes / Advance Treatment Stages 6. Average Flow, Influent & Secondary Effluent Characteristics 7. Amount of Water Treated by Advance Treatment & its Reuse 8. Violations & Operational Problem 9. Conclusion

4 Prior to April 2003, the WWTP conditions were poor There was a Wastewater Treatment Plants but:- The aging old Lagoons were with Broken Side Walls & Non-Operating Surface Aerators

5 Continue : Condition of the Old Plant Broken Inlet Pumps Damaged Inlet Works Broken Grit Chamber Non-Working Grit Classifiers

6 The surrounding areas used to suffer from: Water Logging accompanied with Septic Black Sewage, having odor & environmental nuisance Untreated Effluents - used to be pumped into Red Sea causing negative impacts on the marine environment.

7 Jeddah Industrial City Management was aware & concerned about the Problem and need to resolve it. Consequently, They were seeking a Professional Company that could Provide Total Solution to the Existing Problem Request for Proposal was announced on International Level through WORLD BANK

8 On 1 April 2003, Jeddah Industrial City Management Awarded the BOT Contract to ICDOC To Manage the Existing Old WWTP To develop New Wastewater Treatment Facilities in order to Serve the Jeddah Industrial City.

9 ICDOC Rehabilitated some of the damaged Unit Processes In order to start its Operation to the best of its abilities

10 Extensive Planning was done & Within a quite Short time, the old facilities were rehabilitated for Emergency Operation by : Repairing the Pumps, Valves, Gates & Distribution Chambers etc. Repairing of Surface Aerators etc. Addition of Various Chemicals Applying Various Operational Techniques

11 Pilot Plant Studies were conducted to select the Feasible Process & Design

12 During Operation of Old facilities, Simultaneously.. Design of The New Wastewater Treatment Plant * Feasibility Studies by Operating Pilot Plant * Construction of Civil Work * Execution of Electro-Mechanical work was also in progress

13 Efficient Project Management Techniques were used during the Construction of the New Plant The Project Completed on Scheduled Time

14 Apart from ICDOC Managers, Consultants & Engineers International Company - DHV & Local Companies like Muhaidib Contracting Co., Saudi Berkfeld (Wetico) & Saudi Tumpane were the main Consultants & Contractors during the whole Project Execution

15 Now There Exists a Most Modern Jeddah Industrial City Wastewater Treatment Plant Located in the South of Jeddah (21 o N, 39 o E) to Serve more than 550 factories in various phases of Jeddah Industrial City

16 The Set Objectives of the JIC-WWTP are to :-: 1. Contribute in Serving the Jeddah Industrial City for treating its Wastewater. 2. Provide High Quality Water to some Industries to cut down the Water demand. 3. Satisfy the Client (JIC-Management) & Meteorology & Environmental Protection Agency (MEPA) by maximizing wastewater collection & Treatment in order to Contribute in Protection of the Environmental Pollution.

17 General Layout of JIC-WWTP

18 Process Flow Diagram of the JIC - WWTP

19 JIC-Wastewater Treatment Plant Design Details: Process Name Average Daily Flow Peak Flow Designed Influent & Effluent Characteristics: Parameter ph COD BOD Suspended Solids Influent 5 11 Activated Sludge (Carrousel System) 25,000 m 3 /day 40,000 m 3 /day 3000 mg/l (75,000 Kg/d) 1500 mg/l (37,500 Kg/d) 2000 mg/l (50,000 Kg/d) Secondary Effluent mg/l 25 mg/l 15 mg/l Total Kj.. Nitrogen 60 mg/l (1,500 Kg/d) 10 mg/l

20 MEPA Standards Meteorology & Environmental Protection Administration (MEPA). Environment Protection Measures, Document No , Year Wastewater Treatment Plant Direct Discharge Standards Primary Standard (Physiochemical) Parameters Floating Material Total Suspended Solids Temperature Secondary Standard (Inorganic Chemical) : Parameters Ammonia Arsenic Cadmium Selenium Total Phosphate Zinc Secondary Standard (Organic Chemical) : Acceptable Level None Visible 15 mg/liter Table 1-1 : Appendix of the Contract To be Determined Acceptable Level Parameters Total Organic Carbon Total Kjehldahl Nitrogen Total Chlorinated Hydrocarbons Acceptable Level 50 mg/liter 10 mg/liter 0.1 mg/liter

21 At Present There are about 580 factories in the area Out of which 565 are connected to our Sewerage Network Growth of Factory Connections in the Year Jan Feb Mar Apr May Jun No. of Factories Connected Jul Aug Sep Oct Month Only 2.5 % factories are still not connected.

22 Factories, which are the Major Contributors of Flow include the following types :-: Metal Industries Plastic Packing Industries Carpet Manufacturing Factories Soap & Detergents Factories Glass Manufacturing Factories Cooking Oil Producing Factories Food & Beverage Factories Water & other Food Items Housing Compounds / Labor Camps

23 25,000 20,000 15,000 10,000 Average Daily Flow to the JIC-WWTP Since Jan Till now Jan-06 Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07 Apr-07 May-07 Jun-07 Jul-07 Aug-07 Sep-07 Oct-07 Nov-07 Month Daily Average Flow (m3/d)

24 Influent to the Plant Inlet Chamber Influent Pumps Flow Measurement

25 Grit Removal Chamber & Classifier Grit Chamber Grit Classifier

26 Primary Sedimentation Tank / Oil Removal Primary Sedimentation Tank Oil & Grease Dispose off Tank

27 Aeration Tanks (Carrousel System) Where the Organic Matter is converted to CO 2, H 2 O and New Cells Nitrification & De-nitrification also takes place No. of Aeration Tanks = 2 Total Volume = 65,000 m 3 Total No. of Aerators = 10 Total Power = 1200 KW Total O 2 Supplied = 30,000 Kg/d MLSS = mg/l

28 Secondary Clarifier : Separates the Clean water. Biomass is settled at the bottom which is returned to A/Tanks. Some Sludge is wasted to keep the proper SRT in the System.

29 ICDOC has met The Contractual Requirement of the Effluent Quality Influent Secondary Clarifier Effluent

30 5,000 4,500 4,000 3,500 3,000 2,500 2,000 1,500 1, Influent & Secondary Clarifier Effluent COD for JIC-WWTP (Since Jan Till now) Jan-06 Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07 Apr-07 May-07 Jun-07 Jul-07 Aug-07 Sep-07 Oct-07 Nov-07 COD (Influent) COD (Effluent) Average Influent COD = 2940 mg/l Average Effluent COD = 84 mg/l Overall Efficiency = 97.1 % Acceptable Limit Effluent COD = 150 mg/l Month - Year COD Values (mg/l)

31 Influent & Secondary Clarifier Effluent BOD for JIC-WWTP (Since Jan Till now) Jan-06 Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07 Apr-07 May-07 Jun-07 Jul-07 Aug-07 Sep-07 Oct-07 Nov-07 BOD (Influent) BOD (Effluent) Average Influent BOD = 1498 mg/l Average Effluent BOD = 11 mg/l Overall Efficiency = 99.2 % Acceptable Limit Effluent BOD = 25 mg/l Month - Year BOD Values (mg/l)

32 Influent & Secondary Clarifier Effluent SS for JIC-WWTP (Since Jan Till now) Jan-06 Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07 Apr-07 May-07 Jun-07 Jul-07 Aug-07 Sep-07 Oct-07 Nov-07 SS (Influent) SS (Effluent) Average Influent S.S = 1244 mg/l Average Effluent S.S = 12 mg/l Overall Efficiency = 99.1 % Acceptable Limit Effluent SS = 15 mg/l Month - Year S.S Values (mg/l)

33 Influent & Secondary Clarifier Effluent Total Kjeldahl Nitrogen for JIC-WWTP (Since Jan Till now) Jan-06 Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07 Apr-07 May-07 Jun-07 Jul-07 Aug-07 Sep-07 Oct-07 Nov-07 TKN Values (mg/l) TKN (Influent) TKN (Effluent) Average Influent TKN = 39.5 mg/l Average Effluent TKN = 1.31 mg/l Overall Efficiency = 96.7 % Acceptable Limit Effluent TKN = 10 mg/l Month - Year

34 Influent & Secondary Clarifier Effluent Arsenic for JIC-WWTP (Since Jan Till now) Jan-06 Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07 Apr-07 May-07 Jun-07 Jul-07 Aug-07 Sep-07 Oct-07 Nov-07 Requirement As (Influent) As (Effluent) Month - Year Values (mg/l)

35 Influent & Secondary Clarifier Effluent Chromium for JIC-WWTP (Since Jan Till now) Jan-06 Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07 Apr-07 May-07 Jun-07 Jul-07 Aug-07 Sep-07 Oct-07 Nov-07 Cr (Influent) Cr (Effluent) Requirement Month - Year Values (mg/l)

36 Influent & Secondary Clarifier Effluent Copper for JIC-WWTP (Since Jan Till now) Jan-06 Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07 Apr-07 May-07 Jun-07 Jul-07 Aug-07 Sep-07 Oct-07 Nov-07 Requirement Cu (Influent) Cu (Effluent) Month - Year Values (mg/l)

37 Influent & Secondary Clarifier Effluent Nickel for JIC-WWTP (Since Jan Till now) Jan-06 Sep-07 Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07 Apr-07 May-07 Jun-07 Jul-07 Aug-07 Oct-07 Nov-07 Ni (Influent) Requirement Ni (Effluent) Month - Year Values (mg/l)

38 Influent & Secondary Clarifier Effluent Lead for JIC-WWTP (Since Jan Till now) Jan-06 Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07 Apr-07 May-07 Jun-07 Jul-07 Aug-07 Sep-07 Oct-07 Nov-07 Pb (Influent) Pb (Effluent) Requirement Month - Year Values (mg/l)

39 Influent & Secondary Clarifier Effluent Zinc for JIC-WWTP (Since Jan Till now) Jan-06 Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07 Apr-07 May-07 Jun-07 Jul-07 Aug-07 Sep-07 Oct-07 Nov-07 Zn (Influent) Zn (Effluent) Requirement Month - Year Values (mg/l)

40 ICDOC has continued further. Additional Pilot Plant Studies have been carried out to Enhance the Water Quality to Provide High Quality Water to the Factories for their use

41 Pilot Studies on the State of Art Advanced Treatment Facilities

42 Then ICDOC Added Sand Filtration

43 Ultra-Filtration by Membrane To Enhance the Quality & Protect the further facility

44 Reverse Osmosis Plant : SCADA System Membranes to remove the Total Dissolved Solids Electrical Control Panel

45 NOW, ICDOC Produces A VERY HIGH QUALITY WATER

46 Water Produced After R.O. Process Average Daily Water Production after Revese Osmosis Since Jan Till now 6,000 5,500 5,000 4,500 4,000 3,500 3,000 2,500 2,000 1,500 1, Nov-06 Dec-06 Jan-07 Feb-07 Mar-07 Apr-07 May-07 Jun-07 Jul-07 Aug-07 Sep-07 Oct-07 Nov-07 Daily Average R.O Water Produced (m3/d) Month

47 Present Water Production & Reuse: Average Daily Production : Maximum Daily Production : Total Water Produced in a Year (From Nov 2006 till November 2007) : Water Quality : ph Total Dissolved Solids Turbidity Total Suspended Solids Chloride Total Hardness COD, BOD T.K.N mg/l NIL NIL 17 mg/l 13 mg/l 4,274 m3/d 7,331 m3/d 1,560,010 m 3 (One Million Five Hundred Sixty Thousand and Ten m 3) Not Detectable Not Detectable

48 Our Water is Reused by:- Various Factories like : Middle East Paper Company (MEPCO) Carpet Factories Glass Manufacturing Factories Tankers take away An Average of tankers (Capacity 20 m 3 ) take away the high quality water to various locations in the Industrial City for Miscellaneous usages

49 JIC WWTP has a well equipped Laboratory that is capable of doing all the required analysis -ph -Alkalinity -Chloride -SettleableSolids - Chemical Oxygen Demand (COD) - Biochemical Oxygen Demand (BOD) - Total Suspended Solids (TSS) -Oil& Grease - Total Kjeldahl Nitrogen - Ammonia Nitrogen - Nitrite, Nitrate - Nitrogen.. & so on For Process Monitoring & Control

50 Atomic Absorption Unit for the Analysis of Heavy Metals - Arsenic - Lead - Cadmium - Nickel - Copper - Selenium - Zinc - Ag etc.. etc To confirm the Final Effluent Standards as per the Requirement of MEPA

51 Microbiological Conditions are Monitored with the help of Microscope

52 Every Plant has some exceptional cases of Ups & Downs So, is our Plant But, WE always try hard to take Maximum Care to Control the Upsets by our Experts.

53 Examples of Violations & Upsets: We do have Strict Regulations & Monitoring Program, But from time to time, some the factories dump unusual substance without our knowledge These substance include Excessive Oil & Grease, Paint, Color, Some Toxic material etc

54 Which leads to some Serious Problems to our Plant Abnormal Scum Generation in A/Tanks Poor Quality of Secondary Clarifier Effluent

55 Problems to our Plant Excessive Sludge Accumulation in Inlet Works

56 Sludge Handling Facilities Our Secondary Sludge is well digested as we keep the Sludge Retention Time in Carrousel System in the range of 12 to 20 days. Primary Sludge is Thickened and digested in Aerobic digesters for more than 15 days Sludge Thickener Aerobic Sludge Digester

57 All the Sludge is Dewatered by Centrifuge To Reduce the Volume for Easy Disposal

58 CONCLUSION: JIC-WWTP is a True Model of what ICDOC can deliver for Effective Treatment and Re-use of the Industrial Wastewater in industrial cities in the Kingdom, and for Reshaping the Management of the Wastewater Treatment and reuse by integrated and advanced approaches.

59 Thus, We Meet Our Aims & Objectives 1. Contribute in Serving the Jeddah Industrial City for treating its Wastewater. 2. Provide High Quality Water to some Industries to cut down the Water demand. 3. Satisfy the Client (JIC-Management) & Meteorology & Environmental Protection Agency (MEPA) by maximizing wastewater collection & Treatment in order to Contribute in Protection of the Environmental Pollution.

60 Thank You for Your Kind Attention.

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