Introduction of project for upgrading industrial wastewater treatment and reducing CO 2 emissions in Indonesia by aerator

Transcription

1 Introduction of project for upgrading industrial wastewater treatment and reducing CO 2 emissions in Indonesia by aerator Jakarta, Indonesia, 27 th September 2017 EMATEC (Environmental Management and Technology Center) MURC (Mitsubishi UFJ Research and Consulting) SUZUKI (Suzuki Industry)

2 Introduction of team Introduction of our team EMATEC, MURC and SUZUKI have established consortium for promoting industrial wastewater treatment in Asian countries by Aerator technology in Now we are running 2 aerator projects in Indonesia supported and funded by MOEJ (Ministry of the Environment of Japan). EMATEC EMATEC (Environmental Management and Technology Center) is a foundation for environmental monitoring in Osaka which is established by Osaka prefectural government. EMATEC is a representative of the consortium and in charge of environmental monitoring. MURC MURC (Mitsubishi UFJ Research & Consulting Co., Ltd.) is a consulting company in Tokyo and a major member of Mitsubishi UFJ Financial Group. In the team, position of MURC is a project coordinator and in charge of CO 2 reduction. SUZUKI SUZUKI (Suzuki Industry Co., Ltd.) is an environmental research and manufacturing company in Kyoto. Role of SUZUKI is to analyze situation in each treatment facility and to provide detailed aerator installation plan. Also, aerator is provided by SUZUKI. 1

3 Introduction of Aerator 2 What is aerator? Aerator is an aeration device for industrial and domestic wastewater treatment facility. Mainly aerator is installed at aeration tank and/or equalization tank. In Japan, more than 600 factories are using SUZUKI aerator. Compared with other conventional aeration devices (diffuser, surface aeration system, air mixer etc.), aerator has advantages in aeration capacity and electricity consumption at blower. Dimension of aerator Dia. Len. Materials Weight 125mm 680mm SUS, ABS 8kg Unit air capacity m 3 /min Aeration area 6.0m 3 Aerator

4 Introduction of Aerator Aerator installation Aeration by aerator Installation of aerator Aerator layout at aeration tank 3

5 Introduction of Aerator Mechanism of aerator Air from blower is mixed with wastewater at guide vane in the bottom of aerator and produce strong upward swirling flow. During swirling process, air is diffused to minute bubble at the inside wall of aerator. Strong swirling flow with minute air bubble Guide vane Air from blower Wastewater flow 4 Bottom

6 Introduction of Aerator 5 Advantages of Aerator Aerator generates strong air and wastewater circulation in tanks with less air pressure loss (almost zero loss) compared with conventional diffuser. This function contributes to reduce electricity consumption at blower and CO 2 emissions. <Advantages of Aerator> Reduction of organic pollutants in wastewater Increase of wastewater treatment capacity 30 50% Reduction of electricity consumption (electricity cost reduction and CO 2 reduction) Maintenance free more than 10 years Reduction of residual sludge Less odor from aeration tank Easy installation

7 Example of aerator installation Project outline Aerator installation project (private company project) for industrial wastewater treatment facility at industrial estate in Thailand. Project duration: January 2017 May 2017 Condition before project Item Type of wastewater BOD concentration DO concentration Wastewater amount Aeration device Condition Mixed wastewater from industrial estate <500mg/L 0.5mg/L 18,000 m 3 /day Diffuser Previously used diffuser 6

8 Example of aerator installation Aerator installation layout Number of aerator Tank1: 80 units Tank2: 90 units Number of blower Before: 11kW x 10 units After: 55kW x 1 unit 7

9 Example of aerator installation (DO) Tank1 Tank2 Before After Result DO has been improved by 280% in tank1 and by 130% in tank2. Average DO in tank1 increased from 0.5 mg/l to 1.9 mg/l. Average DO in tank 2 increased from 0.9 mg/l to 2.1 mg/l. After Before 8

10 Example of aerator installation (Electricity) 9 Electricity consumption before and after project Item Unit Before After Difference Air flow from blower m 3 /min Number of blower Unit Blower capacity kw Electricity consumption kwh/year 963, , ,309 Electricity Unit Price Baht/kWh 3.3 Electricity cost Baht/year 3,179,880 1,419,960-1,759,920 Result As aerator needs less air pressure than diffuser, existing old blowers (11kW x 11units) were replaced by a new blower (55kW x 1unit). As a result of blower replacement, electricity consumption was decreased by 55%. Yearly electricity reduction is estimated as 533 MWh/year and amounts 1,760,000 Baht (around 53,000 USD). Yearly CO 2 reduction will be around 320 tco 2 /year.

11 Introduction of current projects in Indonesia For leather industry ( ) This project focuses on how to increase capacity of organic wastewater treatment at a wastewater treatment facility in leather industrial estate. Shorter retention time Since aeration capacity of aerator is stronger than diffuser, retention time at aeration tank can be shortened and amount of wastewater can be increased. For rubber industry ( ) This project focuses on electricity reduction of blower for aeration tank in rubber industry without negative impact to aerobic treatment at their wastewater treatment. 10 Pressure loss reduction Since air pressure loss at aerator (80mmAq) is much smaller than diffuser (1,000mmAq), necessary electricity power for blower running can be reduced. Intermittent air supply Since aerator enables intermittent air supply from blower (diffuser needs continuous air supply), blower operation can be controlled intermittently and electricity consumption can be reduced.

12 Project at leather industry background The target facility collects wastewater from around 100 leather processing factories and treats industrial wastewater by diffuser. Now, wastewater production from factories are increasing and reaching almost maximum capacity of the facility because of increase of leather products. Therefore, the Team proposed to substitute existing diffuser by aerator and increase wastewater capacity without expanding aeration tank because there is no space for new tanks. 11

13 Project at leather industry Characteristics of wastewater Fluctuation of ph and flowrate Increasing amount of wastewater Hazardous chemicals such as Cr and high concentration of organic matter (COD 1,000 2,000mg/L) and NaCl Located in the central city, surrounded by residential area No additional lands for installing new tanks Decrease of river water in dry season 12 Sources of wastewater

14 Project at leather industry Solution Replacing diffuser with aerator at aeration tanks for better activated sludge process and reducing sludge Enhancing mixing capacity at equalization tank and improving sedimentation process Consultation for reducing wastewater and chemicals at each factory and introducing recycled wastewater for some processes 13

15 Project at rubber industry Previous condition Before the project, this company (natural rubber company) treated industrial wastewater from rubber producing processes by aeration system with conventional diffuser for meeting provincial wastewater quality standards. WWTP: WasteWater Treatment Pond 14 WWTP1 (4,725m 3 /day) WWTP2 (9,165m 3 /day)

16 Project at rubber industry Target of the project This project aims to enhance wastewater treatment capacity as well as to reduce electricity consumption and cost for renewal of diffuser by replacing existing diffuser with aerator. 7 blowers in total Existing diffuser (WWTP1: 856units, WWTP2: 1,680units) Aerator (WWTP1: 214units, WWTP2: 288units) Electricity reduction at blower 15

17 Project at rubber industry Progress All aerators and other equipment have been installed successfully until July Air flow piping Aerator installation Ultrasonic flow meter Inflow tank 16 Next step During August October 2017, trial intermittent blower running will start operation considering outlet wastewater quality. Electricity reduction at blower will be monitored after blower running schedule will be decided.

18 Project at rubber industry Monitoring items Electricity consumption at blower will be monitored continuously by electricity meter. Electricity consumption in reference scenario will be estimated by using pressure data (before and after aerator installation) and performance data table of blower made by blower manufacturer. If BOD (or COD) data exceeds wastewater quality standards accidentally, submission of JCM credit will be stopped until wastewater quality will be recovered. 17 Data monitoring equipment

19 Contact Kiyoshi SANNO ( 三納清司 ) k-sannou@ematec.or.jp Hiroyuki UEDA ( 植田洋行 ) hiroyuki.ueda@murc.jp 18

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