23/Jan./2019
Bandung, Indonesia

Co-benefits Project
On Wastewater treatment
For Fish Processing Industry
Nihon Suido Consultants Co., Ltd.
Environmental & Resource Engineering Department
Workshop on WEPA Action Program in Indonesia. 23‐24th January, 2019.
Application of Total Maximum Daily Loads (TMDLs) for Effluent Discharge Permit and Capacity
Building for Local Officials to Implement the TMDLs

Contents of today’s presentation
1. Overview of Co‐benefits projects on FPI
2. Wastewater management for FPI in Indonesia
3. Demonstrative experiment using wastewater
treatment facility
3.1 Objective and outline of demonstration
3.2 Selection of demonstration site
3.3 Wastewater treatment technology for experiment
3.4 Result of the experiment
4. Preparing the guideline for wastewater treatment
5. Implementation of capacity building１1. Overview of Co‐benefits projects on FPI(1) Objective of the project
Reduce pollution load to public waters by introducing excellent wastewater
treatment technology of Japanese companies in order to promote measures for
wastewater treatment in Indonesian fish processing industry(FPI).
At the same time, contribute to the prevention of global warming by reducing
the generation of greenhouse gas from wastewater that is drained untreated
and by introducing a treatment method which consumes less energy than theusual method. Transmit the technology by conducting capacity‐building in thesurvey process as well.
What is Co‐benefits Approach
Measures for pollution
control

Co‐benefit

Measures for reducing
GHG emission

The procedure of Co‐benefits Approach
PromoteCo‐benefits
Approach

Selectco‐benefits
technology

Evaluation of
Quantitative
effectIntroducing
co‐benefits
project2

1. Overview of Co‐benefits projects on FPI(2) Contents of projects1) 1st stage (FY2011‐FY2014)• Identify the problems on fish processing industry and survey related legal
regulations in Indonesia• Select a factory for demonstration, survey on co‐benefits type wastewater
treatment technologies of Japanese companies and select technology tointroduce at site in the factory (aerobic treatment, SW method)• Install demonstration facility at the factory, operate it, analyze monitored
data and assessment of effect caused by introduction2) 2nd stage (FY2015‐FY2017)• To achieve more co‐benefits effects, improve the wastewater treatment
facility introduced in the 1st phase• Install ABR before SW facility and operate demonstration facility, analyze
measurement result.
• Prepare the guideline for fish processing industry using the result of
demonstrational experiment.
※ Conduct capacity building annually in Indonesia and Japan,
workshop, seminar, Japan study tour etc.
3

2. wastewater management for FPI in Indonesia(1) Condition of environmental management
 Environmental management of fish processing industry is evaluated as the worst
level in PROPER System, promoted by Ministry of Environment. Black and redevaluations occupy 90% in FY2012 evaluation result (blue indicates the level thatsatisfies the effluent standard, and red and black indicate the low management level).
hospital
hotel
energy Power Plant
electronics
metal platingGoldsmelting metalGreen

ceramics
rubberBluechemicalRed

plywoodBlacktextilesfood and drink
flour
fish processing
mineralcoal mine
0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

4

2. wastewater management for FPI in Indonesia(2) Measures to improve wastewater management
 Necessary to introduce legal systems and measures, such as technical guidance,in order to promote installment of appropriate wastewater treatment facilities andoperate it properly.
No wastewater
treatment facility

Introduction ofwastewater
treatment
facilities by laws
and system(PROPER) etc.

Factory
Inflow tank(raw water pump)Effluent standard
is not met

Contact aeration
tank
B

B

B

Aeration blower
Discharge tothe river

Settling tank

Treated watertank (pump)

Even if the fish processing
factory has wastewater
treatment facilities, thetreatment is not efficient (notbiological but physicochemicaltreatment)

Technical capacity
to select a
wastewater
treatment method
according to thewastewater
quality andoperate properly

Improvement ofcompliance andtechnical capacity
using the systemof qualificationsuch as pollution
control manager
Development,
research, educationof wastewater
treatment
technology byuniversities andresearch institutes

Offer ofmanagement
support tools
through training,
guidelines, etc.

5

3. Demonstrative experiment using wastewater
treatment facility
3‐1. Objective and outline of demonstration
Objective
To promote to spread co‐benefit type wastewater treatment technology for fishprocessing industry in Indonesia using demonstrative experiment.

Outline1. Select an area which boasts fish processing industry, and select a factory at
this area which has problem on wastewater treatment
2. Select appropriate co‐benefit type wastewater treatment technology, design
and install experimental wastewater treatment facility at the factory site
3. conduct experiment using the facility and estimate quantitative co‐benefit
effect.(1) Select factory(1)Plan Demonstrative Experiment Select an area Select factory(3) Operation and Maintenance Operate and maintain WTS
 Monitor water quality, etc
 Collect operating data Prepare operating plan Set up Wastewater Treatment System (WWTS)
Estimate effect Analyze operating data
(water quality, electric consumption etc.)
 Estimate effect of co‐benefit type WWTS

6

3‐2. Selection of demonstration site(1) Site selected for demonstration
 Conducted on‐site survey for 3 sites (as below)
proposed by Ministry of Environment in Indonesia
 Selected target area and factory in Jembrana regency
Muara Angke

BitungJembrana

Province,area

Muara Angke,
Special Capital
Province of Jakarta

Bitung, North
Sulawesi
Province

Jembrana
Department, Bali
Province

Fish catch (t)About 20,000

About 850,000

About 25,000

Population

10,000178,000

37,800AdoptionFish meal factory7

3‐2. Selection of demonstration site(2) Production process of selected fish processing factories● Density of organic substances is very high due to the process of smothering ingredients.
Oil is collected by centrifuge, but drained without being removed completely.

① Cooker machine② Drier③ Tricanter83‐3. Wastewater treatment technology for experiment(1) Process of wastewater treatment
 Characteristics of wastewater of fish meal factory are (1) variation of flow rate,(2)highly density organic wastewater (COD:60,000mg/L) and (3)High SS and oil andgrease.
 Wastewater treatment is necessary to be strong to shock load of amount ofwastewater, and be able to reduce organic mater, SS and oil and grease.
Desulfurizing
process

Bio‐gasAnaerobic treatment processPre‐
treatment
process

Treatment of oil&grease and SS

Utilization
process of
bio‐gasTreatment
process of
bio‐gasAnaerobic
Process（ABR method)

Preservation,
Bio‐boiler etc.

Aerobic treatment process
Aerationtank(SW method)

ClarifierTreatment of highorganic matter※Bio‐gas include about 60% methane (CH4) and 40% carbon dioxide (CO2).

93‐3. Wastewater treatment technology for experiment(2) Characteristics of ABRConstruction

Biomass

Operation•Simple design•No moving parts•No mechanical mixing•Inexpensive to construct•High void volume•Reduced clogging•Reduced sludge bed expansion• Low capital and operatingcosts•No requirement for biomass withunusual settling properties•Low sludge generation•High solids retention times (SRT)• Retention of biomass without
fixed media or a solid‐settlingchamber• No special gas or sludge
separation required• Low hydraulic retention times(HRT)•Intermittent operation possible• Extremely stable to hydraulicshock loads•Protection from toxic materials in
influent• Long operation times without
sludge wasting The best characteristicof ABR is to be able toadjust reactor volume
for hydrolysis, acidformation andmethane formationaccording to water
quality level.
 For example, in case of high organic substance, volume for hydrolysis can be large. So ABRis flexible toward variation of water quality.
 ABR can control pH in Methane formation phase without no or less alkaline agent by
returning treated water, so operation cost tends to decrease.
10

3‐3. Wastewater treatment technology for experiment(3) Flow chart of Anaerobic process (ABR)
Oil separation

Scum removal

Acid Fermentation

Gas Utilization

Methane Fermentation11

3‐3. Wastewater treatment technology for experiment(4) Characteristics of Aerobic process (Swim Bed method)● Swim Bed method can make relatively big microbes stuck on the fringe installedin the tank and stabilize in the reaction tank. It can thus keep SRT(Sludge RetentionTime) for a long time and dissolve oil.

Water flow

Swim Bed (fringe)

Swim Bed in the tank

Fringe swims up and down using the water flow andmicrobes continuously separate and stick. It keeps thesludge in the tank in high density, and microbes which are
Swim Bed Tank
suitable for oil dissolution increase● Thanks to Swim bed (fringe) on which microbes stick, there is no problem of
clogging nor simultaneous separation unlike the ordinary fixed floor.
123‐3. Wastewater treatment technology for experiment(5) Flow chart of aerobic process (Swim Bed system)D
A: Equalization tankA

B

B: Swim Bed tank

C: ClarifierC
Treated water
D: Measuring tank13

3‐4. Result of the experiment(1) Monitoring items for evaluation(1) Equalization
Tank(2) Anaerobic
Treated Tank

(3) Effluent
Tank

Water Temperature

☆●

☆●

☆●

Thermometer

pH

☆●◎

☆●◎

☆●◎

pH meter,

CODcr

●◎

●◎

●◎

HACH (colorimeter)

BOD

◎

◎

◎

SS, NH4-N

●◎

●◎

●◎

T-N, Cl2, Oil & Grease

◎

◎

◎

Electricity Consumption

◎

◎

◎

Bio-gas (Methane gas)

◎

◎

◎

Measurement Items

Measurement equipment(Simplified measurement)

MLSS meter, Pack test
Each process (ABR,SW)

BiogasFlow rate
CH4

Measurement items
pH, Water Temp.(everyday)
CODcr, SS, NH4 ‐N (3 times a week)

BiogasP(1) Equalization
Tank

Scum Removal Tank

Acid Fermentation Tank

Methane Fermentation Tank

Equalization
Tank
Influent

Raw
Water
Tank

P
P
P

Measurement items
pH, Water Temp.(everyday)
CODcr, SS, NH4‐N (3 times a week)P

Sludge Tank

(2) Anaerobic
Treated Tank

Effluent

Measurement items
pH, Water Temp.(everyday)
CODcr, SS, NH4 ‐N (3 times a week)
Anaerobic
TreatedWater tankEffluent Water
Tank

P

Swim Bed Tank (Aeration Tank)

Sedimentation Tank

Effluent(3) Effluent Tank

14

3‐4. Result of the experiment(3) Removal ratio of water quality
ABR (Anaerobic treatment) Removal ratio of COD is more than 90％.
 Removal ratio of NH4 is about 70％, Oil&Grease is about 50％.

SW method (Aerobic treatment) Removal ratio of COD is more than 99％.
 Removal ratio of NH4 is more than 90％, Oil&Grease is about 70％.
100%
Removal ration of each parameter by SW(%)

Removal ration of each parameter by ABR(%)

100.0%

80.0%

60.0%

40.0%

20.0%

0.0%

80%

60%

40%

20%

0%

COD

NH4

TSS

Oil&Grease

ABR (Anaerobic treatment)

COD

NH4

TSS

Oil&Grease

SW method (Aerobic treatment)15

3‐4. Result of the experiment(4) Electricity consumption of each water treatment process
 The electricity consumption per removed COD of SW method was about1(kWh/kg‐COD load) and 1/3 of the average of activated sludge treatment
method in Indonesia
 The electricity consumption of ABR was about 0.3 (kWh/kg‐COD load) and 1/3
of SW method.
 Pressure of biogas in gas holder was more than 5kPa
 Methane concentration of bio gas was from 65% to 70%
Electricity consumption per removal
COD load(kWh/kg）

4.0

Average COD of wastewater treatment
facilities in factories in Indonesia:
2.7kWh/kg

3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0

ABR

SW method

Factory A

Factory B

Factory C

Factory D

16

3‐4. Result of the experiment(6) Reduction of electricity consumption in factory
Traditional treatment（Activated sludge）
Flow rate
15m3/dActivatedsludge(first stage)

Wastewater
COD 60,000mg/L

Activatedsludge(second stage)

Treated water
COD 3,000mg/L

Treated water
COD 150mg/L

Co‐benefit type treatment（ABR+SW)
Bio gas450m3/dFlow rate
15m3/dABR
Wastewater
COD 60,000mg/L

Generator
SW method

Treated water
COD 9,000mg/L

Treated water
COD 180mg/L＜COD removal ratio95％＞ ＜COD removal ratio95％＞＜COD removal ratio 85％＞ ＜COD removal ratio 98％＞

【Calculation of electricity consumption】
・first stage of activated sludge
15×（60,000‐3,000）×2.7/1,000=2,309kWh/d・second stage activated sludge
15×（3,000‐150）×2.7/1,000=115kWh/d・Total electricity consumption=2,309＋115=2,424kWh/d【 Calculation of electricity consumption 】
・first stage (ABR)
15×（60,000‐9,000）×0.3/1,000=230kWh/d・second stage (SW method)
15×（9,000‐180）×1.2/1,000=159kWh/d・ Total electricity consumption=230＋159=389kWh/d・ Generated electricity（bio‐gas765kg‐COD×0.35/0.6）=450×0.6×35.8×0.35/3.6=940kWh/d
Surplus of electricity: 551（=940‐389）kWh

Difference between traditional treatment
and co‐benefit type treatment: 2,975kWh/d

17

4. Preparing the guideline for wastewater treatment
4.1 Preparing formation of the guideline

Chairman ofCommittee（ITB)
Expert ofwastewater
treatment
Working teamfor preparing
guideline

Ministry ofenvironment
and forestry（KLHK)

Ministry ofenvironmentof Japan（MOEJ)
Japanese
consultants（NSC)

Guideline preparing committee

Expertregarding fishprocessing
industry
Manager andoperator of fishprocessing
factory

Spreadandutilizeguideline

Localgovernment
person in chargeof wastewater
management

Stakeholder and participants of workshop/seminar18

4. Preparing the guideline for wastewater treatment
4.2 Contents of the guideline194. Preparing the guideline for wastewater treatment
4‐3. Spread and Utilize Guideline at the factory
Existing
treatment
facility

Survey on producing process and water
quality of effluent and condition ofwastewater treatment
No facility

Plan to introduce the co‐benefit typewastewater treatment facility to meet
wastewater quality standard of this factory

Identify the problem of waste water
treatment and give technical assistance toimprove operation more effectively.

Compile the information for improving
guideline which was obtained throughtechnical assistance20

5. Implementation of capacity building
Outline of capacity building
No. Event& location
Presenter
ActivityWorkshopin Ministry of Environment of Japan  Promotion of co‐benefit approach by MOEJ
(MOEJ)
Jembrana(1) Outline of demonstrative equipment in Jembrana
regency in Bali Japanese consultants(Nihon Suido Consultants)
 Interim report of demonstrative equipment(experiment Installation and operation of demonstrative equipment
Manager of FPI (Indonesian)site)
Person in charge of wastewater  wastewater regulation for fish processing industry at
regulation (prefectural government)
Ibaragi prefecture
Japan study tour
Professor of University
 Wastewater treatment technology(TokyoandExpert of Japanese wastewater  Site visit at research center of Japanese wastewater
nearbyengineering company
engineering company(2)
prefectureinManager of fish processing factory  Site visit at fish processing factory complex
Japan)
complex(common wastewater treatment facility)
Manager of factory of fish or food Site visit at the factory of food processing industry
processing company(anaerobic wastewater treatment facility)
Ministry of Environmental pollution  Introduction of policy of environmental management
control MOEF, KLHKof KLHK
Ministry of Environmental pollution  Introduction of pollution control from fish processing
control MOEF, KLHK
industry in Indonesia
Workshop
Ministry of Environment of Japan  Promotion of co‐benefit approach by MOEJ
in Jakarta(3)(MOEJ)
 Operation of demo plant and evaluation of co‐benefit
Japanese consultants
effect(Nihon Suido Consultants)
 Estimation of co‐benefit effect in Indonesia
21

5. Implementation of capacity building
Workshop in Indonesia (No.1 at previous table)

Site visit of experimental site and factory in Japan (No.1, No2)22

5. Implementation of capacity building
Lecture by Japanese expert in Japan study tour (No2,No3)● Lecture regarding wastewater regulation and wastewater treatment
technology

Lecture regarding wastewater
regulation from expert of prefecture

Lecture regarding wastewater
treatment technology fromacademic expert

23

Acknowledgement
Co‐benefit project have been conducted with KLHK generous
cooperation, especially Ms. NOOR RACHMANIAH, Deputy
Director of Sub Directorate Water Pollution and Domestic
Waste Control, Directorate of Water Pollution Control,
Directorate General for Pollution and Environmental
Degradation Control , Ministry of Environment and Forestry.
We appreciate kind cooperation of KLHK staff.

24

TERIMA KASIH BANYAK

Nihon Suido Consultants Co., Ltd.
Environmental & Resource Engineering Department