Introduction of model project for
upgrading industrial wastewater
treatment and reducing CO2
emissions by aerator
Bandung, Indonesia, 23rd January 2019

EMATEC (Environmental Management and Technology Center)
MURC (Mitsubishi UFJ Research and Consulting)
SUZUKI (Suzuki Industry)

Introduction of implementation team
 EMATEC, MURC and SUZUKI have established consortium forpromoting improved industrial wastewater treatment in South East
Asian countries by “Aerator technology”.
 Currently we are running 2 aerator projects in Indonesia in East Java
province and South Sumatra province.
 Both projects are supported and funded by MOEJ (Ministry of theEnvironment of Japan).
EMATEC EMATEC (Environmental

Management and TechnologyCenter) is a public-orientedorganization for environmental
monitoring, established by
Osaka prefecture.
 EMATEC leads the team and is
responsible for environmental
monitoring and analysis.

1MURC
 MURC (Mitsubishi UFJ Research& Consulting Co., Ltd.), a major
member of Mitsubishi UFJ
Financial Group in Japan, is aconsulting company in Tokyo,
Osaka and Nagoya.
 In the team, role of MURC iscoordination and managementof the project.

SUZUKI SUZUKI (Suzuki Industry Co.,Ltd.) is an aerator developer inKyoto.
 Role of SUZUKI is to analyze
wastewater treatment conditionin each company and provide
customized improvement planby using aerator.

About Aerator
 Aerator is an aeration device forindustrial and domestic wastewater
treatment facility. Aerator is installed at
aeration tank and/or equalization tank.
In Japan, more than 600 factories withhigh organic load in inlet wastewater
have installed SUZUKI aerator.
 Compared with other conventional
aeration devices (diffuser, surface
aeration, air mixer, etc.), aerator has
advantages in aeration capacity andreduction of electricity consumption(costs) at blower.
Specification of SUZUKI aerator type S-1
Dia.

Len.

Materials

WeightUnit aircapacity

Aerationarea

125mm

680mm

SUS, ABS8kg

0.7-1.4
m3/min

6.0m3

2Aerator type S-1 (stainless steel)Mechanism of Aerator
 Air from blower is mixed with wastewater at guide vane in thebottom of aerator and generate strong upward swirling flow. During
swirling process, air is diffused into minute bubble.

Aeration by diffuser

Aeration by aerator

Strong swirling flow
with minute air bubble
Guide vane
Wastewater flow
Air from blower3Bottom

Advantages of Aerator
 Aerator generates strong air and wastewater circulation in aeration

tanks with less air pressure loss (almost zero loss) compared withconventional diffuser.
 This function contributes to increase wastewater treatment capacity
and cut electricity consumption at blower and reduce CO2 emissions.

<Advantages of Aerator>
Increase of wastewater treatment capacity for organic pollutants 30–50% Reduction of electricity consumption (= reduction ofelectricity cost and CO2 emissions) by reduction of air pressure
loss and intermittent operation
 Maintenance free for more than 10 years (blower needs maintenance)
 Easy installation (existing blower and air pipe can be used) Reduction of residual sludge
 Less odor from aeration tank


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Aerator layout

 Aerator is installed on the bottom of aeration tank every 2 - 3 m.

 Existing blower and air pipe can be used. But in our experience in Indonesia, in5

many cases, air flow capacity of existing blower is smaller than required capacity
for existing diffuser. In this case, it is better to change existing blower to stronger
one for better wastewater treatment and effective electricity reduction.

Aerator installation

Checking aerator and preparing pipes
Connecting pipes

6Piping

Aerator installation

Introduction of two projects in Indonesia
 For leather industrial estate (2016-18FY)

 This project focuses on how to increase wastewater treatment

capacity to meet wastewater standard for leather industry.
Solution: increasing aeration capacity
Since organic pollutants from leather
industry is high, sufficient aeration
capacity is requited.

 For rubber industry (2015-18FY)

 This project focuses on electricity reduction at blower in rubber

industry without negative impact to aerobic treatment.

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Solution: Pressure loss reduction

Solution: Intermittent air supply

Since air pressure loss at aerator(80mmAq) is much smaller than diffuser(1,000mmAq), necessary electricity power
for running the blower can be reduced.

Since aerator enables intermittent air
supply from blower (diffuser needs
continuous air supply), blower operation
can be controlled intermittently andelectricity consumption can be reduced.

Project for leather industrial estate background The target facility collects wastewater from around 100 leather

processing factories and treats industrial wastewater by diffuser.
Currently, wastewater production from factories are increasing andreaching almost maximum capacity of the facility because ofincrease of leather products.
 Therefore, the Team proposed to substitute existing diffuser byaerator and increase wastewater capacity without expanding
aeration tank because there is no space for new tanks.

Previous wastewater treatment in leather industrial estate8

Project for leather industrial estate 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

Sources of pollutants (leather processing factory)9

Project for leather industrial estate 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 eachfactory and introducing recycled wastewater for some processes.

Field survey

10Outlet to riverProject for leather industrial estate Result (COD)

3,000

Aeration tankLine Aaerator

Aeration tankLine B

COD(mg/L)

2,500

Diffuser

2,000
1,500
1,000500
031-Aug In the facility, since there are 2 aeration

4-Sep

Inlet

Aerator

5-Sep

AverageDiffuser

COD concentration in outlet wastewater
100%
90%
Remaining COD fraction

tanks, we installed aerator in one tank(line A) for evaluation and comparedtreatment capacity with diffuser (line B).
 After installation, COD concentration inLine A is reduced to 144 mgCOD/L
compared with line B of 387 mgCOD/L.
 New national regulation in July 2018 forleather industry is set to 200 mgCOD/L.
The aerator proofed that aerator can meetthe newest wastewater regulation.
 Line A seems to have additional capacity
for wastewater treatment.
111-Sep

80%
70%
60%
50%
40%
30%
20%
10%
0%
31-Aug

1-Sep

4-Sep
Aerator

Diffuser

5-Sep

Remaining COD fraction

AverageProject for leather industrial estate Result (electricity)
Comparison of electricity consumption at blowers
DateElectricity consumption(kWh/day)Line ALine BReduction(aerator) (diffuser)Line A (aerator)
Blower 1

Line B (diffuser)

Blower 2

Blower 1

Blower 2

Airflow
(m/s)

Temp.
(Celcius)

Airflow
(m/s)

Temp.
(Celcius)

Airflow
(m/s)

Temp.
(Celcius)

Airflow
(m/s)

Temp.
(Celcius)

24-Feb

131

188

30.0%

24.1

58.3

23.6

61.2

23.8

97.0

25.7

75.6

27-Feb

139

204

32.0%

24.0

60.4

23.3

62.3

24.2

119.0

25.8

67.5

28-Feb

141

214

33.9%

23.8

59.7

22.5

61.3

22.9

117.0

25.5

75.0

1-Mar137

207

33.8%

23.7

62.7

21.8

65.0

23.9

100.0

20.5

81.52-Mar

135

206

34.5%

24.2

60.5

23.2

62.5

23.8

115.0

25.5

74.5

3-Mar

131

204

36.0%

23.8

59.0

23.5

61.5

22.8

117.0

23.8

75.8

 Electricity reduction by aerator is around 33% compared with diffuser.

 Blower temperature in Line A is around 60 Degree Celsius but Line B is around 80 and 110

Degree Celsius. This means blower load for Line A is smaller than Line B.
 Annual CO2 reduction is 63 ktCO2/year.
 Initial cost recovery by electricity fee reduction is estimated as 5 – 8 years.

12Project for rubber industry
 Previous condition Before the project, this company (natural rubber company) treatedindustrial wastewater from rubber producing processes by aeration
system with conventional diffuser for meeting provincial
wastewater quality standards.

WWTP: WasteWater Treatment Pond

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WWTP1 (4,725m3/day)WWTP2 (9,165m3/day)Project for 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
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Project for rubber industry
 Installation

 All aerators and other equipment have been installed successfully

until July 2017.

Piping

Aerator installation Ultrasonic flow meter

Inflow tank

 Monitoring Electricity consumption was reduced by 30-40% compared withprevious diffuser treatment without negative impact to outlet
wastewater quality.
 Temporary CO2 reduction in 2018FY will be soon reported to JCM
15 secretariat in Indonesia.

Possible contribution to Citarum river Industries with high organic load in wastewater will be potential

candidate of aerator installation such as; Leather industry
 Textile industry
 Food and beverage industry
 Rubber industry

 Domestic wastewater treatment facility is also candidate of aerator.
 Initial cost recovery will be done in 5 – 8 years. Also, if JCM scheme

will be applied, duration of initial cost recovery will become almost
half.

 We hope to contribute to Citarum river recovery by aerator.

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Contact

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

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