Introduction of project for
upgrading industrial wastewater
treatment and reducing CO2
emissions in Indonesia by aerator
Jakarta, Indonesia, 27th September 2017

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

Introduction of teamIntroduction of our team

EMATEC, MURC and SUZUKI have established consortium forpromoting industrial wastewater treatment in Asian countries by“Aerator technology” in 2014.
Now we are running 2 aerator projects in Indonesia supported andfunded by MOEJ (Ministry of the Environment of Japan).

1EMATECMURCSUZUKIEMATEC (Environmental
Management and TechnologyCenter) is a foundation forenvironmental monitoring in
Osaka which is established by
Osaka prefectural government.
EMATEC is a representative of
the consortium and in charge ofenvironmental monitoring.

MURC (Mitsubishi UFJ Research& Consulting Co., Ltd.) is aconsulting company in Tokyoand a major member of
Mitsubishi UFJ Financial Group.
In the team, position of MURC isa project coordinator and incharge of CO2 reduction.

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.

Introduction of Aerator
What is aerator?

Aerator is an aeration device forindustrial and domestic wastewater
treatment facility. Mainly aerator isinstalled at aeration tank and/or
equalization tank. In Japan, morethan 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

2Dia.

Len.

Materials

WeightUnit aircapacity

Aerationarea

125mm

680mm

SUS, ABS8kg

0.7-1.4
m3/min

6.0m3

AeratorIntroduction of Aerator
Aerator installation

Aeration by aerator

Installation of aerator
Aerator layout at aeration tank3

Introduction of Aerator
Mechanism of aerator

Air from blower is mixed with wastewater at guide vane in thebottom of aerator and produce strong upward swirling flow. During
swirling process, air is diffused to minute bubble at the inside wallof aerator.

Strong swirling flow
with minute air bubble
Guide vaneWastewater flow
Air from blower
4BottomIntroduction of Aerator
Advantages of Aerator

Aerator generates strong air and wastewater circulation in tankswith less air pressure loss (almost zero loss) compared withconventional diffuser.
This function contributes to reduce electricity consumption atblower and CO2 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 CO2 reduction)
Maintenance free more than 10 years
Reduction of residual sludge
Less odor from aeration tank
Easy installation
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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 wastewaterfrom industrial estate<500mg/L
0.5mg/L
18,000 m3/day
Diffuser

Previously used diffuser

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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

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Example of aerator installation (DO)
Tank1

After

DO has been improvedby 280% in tank1 andby 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.

BeforeTank2
After
Before8Result

Example of aerator installation (Electricity)
Electricity consumption before and after project
ItemUnit

BeforeAfter

Difference

Air flow from blower

m3/min5440---

Number of blower

Unit

101---

Blower capacitykW1155---

963,600

430,291-533,309

Electricity consumption kWh/year
Electricity Unit Price

Baht/kWhElectricity cost

Baht/year

Result3.3
3,179,880

1,419,960-1,759,920

As aerator needs less air pressure than diffuser, existing old blowers (11kW x11units) 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 CO2 reduction will be around 320 tCO2/year.
9Introduction of current projects in Indonesia
For leather industry (2016-18)

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 andamount of wastewater can be increased.

For rubber industry (2015-17)This project focuses on electricity reduction of blower for aeration
tank in rubber industry without negative impact to aerobic
treatment at their wastewater treatment.

10Pressure loss reductionIntermittent air supply

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

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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

Sources of wastewater12

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 eachfactory and introducing recycled wastewater for some processes

13Project at 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 at rubber industry
Target of the projectThis 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 at rubber industry
Progress

All aerators and other equipment have been installed successfullyuntil July 2017.

Air flow piping

Next step

Aerator installation Ultrasonic flow meter

Inflow tank

During August – October 2017, trial intermittent blower runningwill start operation considering outlet wastewater quality.
Electricity reduction at blower will be monitored after blower
running schedule will be decided.

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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 byusing pressure data (before and after aerator installation) and performancedata 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.

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

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