13th Annual Meeting of WEPAWEPA International workshop on Industrial Wastewater Management

Sustainable Water Use in Development of Asian Countries

Evaluation and Control of Industrial Wastewater
Discharge based on Material Flow Analysis

Koichi FUJIE, Professor
Institute of Advanced Sciences
Yokohama National University
Sept.26, 2017, Jakarta, Indonesia
1

Contents of this presentation
Categorization of industries
Kind ofproduction process

Kind of wastewater(characterization)

Process configuration
Input/output
Material flow in the process

Improvement of production
Reduction of wastewater

Kind of treatments

Recycle use for what?

Appropriate selection andoperation of treatments

Impact on environment and ecosystem

Conditions of surrounding environments

2

Water flow and use in watershed
Information on industrial activities in the watershed
such as type of industry, water use and wastewater
discharge, pollutants, treatment, recycle, and so on.
Process improvement and reductionof wastewater are required.

Water resource
Watershed
management

Wide variety of industries
Water
intake&distribution
Appropriate treatment is required for theEnvironment
quality standard
Effluent standard
Water pollution load
Flow rate &environment condition

Monitoring

conservation of water environment andDaily withlife low cost and low
water resources
consumptions of energy and materials.

Agriculture
Sewagetreatment

Treatment? Treatment& recycle?
Flow rate, pollutants
and concentration, etc.

Impact on river water quality

Costal area
3

Wastewater treatment process
Configuration of wastewater treatment process: Combination of various unit
separation process based on the given conditions of wastewater and treatment.
W astewater

Preliminary
Treatment

Primary

Secondary

Screening

Coaguration

Activated Sludge

Oil Separation

Sedimentation

Trickling Filter

Advanced Treatment

Effluent

Biological Treatments
Coagulation/Sedimentation
Stripping

pH Control

Floatation

Submereged Filter
Rotating BiologicalContactor

Sand Filtration
Ultrafiltration
Microfiltration
Reverse Osmosis

Chemical Oxidation
1)Wastewater treatment is a separation process.
Disinfection
Simple composition and/or similar properties ofElectrodyalisis
pollutants are the better for separation.
Ion Exchange
2)Selection and combination of unit process can bedone based on the conditions as the quality andquantity of influent, effluent quality, and otherrequirements.
3)We have to know the wastewater for the appropriate selection and combinationof unit process, and that the construction and operation of the wastewater
treatment process consumes energy and additional materials. Trade-off!

4

Countermeasure for industrial wastewater(1) Categorization of industrial process

Industry and production process

Related information and data to be collected
1)Type of industry, raw materials and products2)Production process and material flow3)Wastes and wastewater discharge4)Environmental problems5)Environmental awareness and outlook of operator6)Surrounding environment and public awareness1)Operational condition of the industrial plant2)Source of wastewater and the its information
3)Identification of pollutants and treatability, etc.

Typical industries in the watershed
Public water body5Countermeasure for industrial wastewater(2) Performance improvement of industrial plantIndustry and production process

Information on the plant performance
Material flow analysis on the plant will give;1)Conversion of raw materials,
2)Yield of product and productivity,3)By-products and wastes.
These information and data can be used todiagnose the process and plant.
Optimal operating conditions will be given to
reduce the pollutants discharge, while
increasing the production performance.

Industrial process and plant

6

Countermeasures for industrial wastewater(3)Selection of appropriate wastewater treatments

Kurita Water & Environmental Foundation

Appropriate process of wastewater treatment is selected based on the information anddata of material flow on the production process and the information such as;1)Existing water pollution problems, and those expected in the water body,2)Environmental awareness and outlook/vison of plant manager/administrator, and
3)Surrounding environment and public awareness.
Process configuration, operation and maintenancePreliminary
Influent-pollutants-concentration-flow rate-othersOilseparation

Primary

Secondary

Coagulation
sedimentation

ActivatedsludgeAdvanced
Effluent
Disinfection

examplePerformance, maintenance, problems, energy
consumption, etc. and comments on the process-pollutants-concentration-discharge-recycle-others

Appropriate choice ofwastewater treatment process
Recycle use✖

Discharge

7

Countermeasures for industrial wastewater(4)For sustainable water use in development
Resources andenergy saving

Kurita Water & Environmental Foundation

Increase of productivity

Products
Domestic materials
and energy input

Effective use of limited
water resources

Process and plant
improvement

Appropriate wastewater treatment
with low cost and low consumptionsof energy and additional resources.

Decrease of wastes andwastewater discharge
Recycle use

Discharge✖

Wastes,wastewater,
exhaust gas

Sound water environment

Watershed or regional area8

Chemical engineering approach fordiagnosis of industrial process and plants
Principles of chemical engineering

Balance & Flow：Material, Energy, Momentum, Cash ･･
Rate：Mass transfer, Reaction,････････
Unit Operation：Separation & refining, mixing, other treatments･･
Process & System: Development and design, Analysis and
Evaluation, Operation and Control, Management
Chemical engineering aspects - mass & energy balances; choice of datum, overall & component
balances, simultaneous mass & energy balances, stoichiometry, combustion, recycle & purge
streams: fluid flow; dimensionless groups, viscosity, streamline & turbulent flow, Reynolds
number, roughness, energy losses: pumps; flow-head characteristics, sizing: heat transfer;conductivity, resistance, overall heat transfer coefficients, fouling factors, heat exchangers: unit
operations; definition, categorization, typical applications: flow sheets: safety & environmental
aspects of plant design & operability.
9Material flow analysis in production process

Material Flow (or Balance) Analysis in a Reactor
Reaction： A → R is proceeded in a single stage reactor
Reactant: A

Input
Q
CA0=10CR0=0

reactorθ =1h

OutputQ
CA1=5
CR1

Mixture of
Product: R
Residual reactant: A
Intermediates: I
By-products: X, etc.
Material balance equation ofreactant A in reactor

liquid volume:V1
θ : hydraulic retention time)

Energy for
operation

Volumetric Efficiency=Q(CR1-CR0)/V1
Conversion :x=1-CA1/CA0
101)MFA on industrial process
Material flow analysis on industrial process
Energyrecycleseparation

Raw material

mixingReservoir

reactorseparation

separation

Wastes 3

Products
wastes１

Wastewater 1 Wastewater 2 wastes２

Wastes & wastewater
What kind of and how much materials coming in and going out at each unit operation can be known!

Material flow analysis on the process will give information of:
Productivity, yield, wastes & wastewater discharge, etc.
Amount and composition of wastes and wastewater can be clarified
11

Improvement of industrial process for the
reduction of wastewater discharge
Washing water
Previous process
Evaporation

Products

Products

WastewaterElectro deposition

12

Improvement of industrial process for the
reduction of wastewater discharge
Previous process
Evaporation

Products
Products

Process
water

Evaporation

Products

Water supply

Products

Recycle use

Electro deposition

Wastewater

Recycle use
Electro deposition

UF
Recycle use

Improved processfeatured UF filtration

With incorporation of UF membrane, the filtrate can used for products washing.
Closed process can be achieved for electro-deposition.
13

Onsite treatment and recycle ofwastewater in unit industrial process
Process
Water
PROCESSPROCESS

RecycleSimple onsite
treatment and recycle

COAGULATIONPRODUCT

BLOW WATERPROCESSSEDIMEN TATIONPROCESSBLOW WATERD

FILTRATIONCBLOW WATERB

FILTRATIONA

RecycleRecycleION EXCHANGE

RAW
MATERIAL

COAGULATIONFILTRATIONACTIVATED CARBONRECYCLEEFFLUENT

Simple treatment of
mixed similar wastewater

Final treatment in small
process for discharge
and recycle
14Advanced wastewater treatment and recycle
system of industries based on material flow analysis
Previous system

To meet the stringent effluent
standard, additional and highcost treatments are needed.

Process water

Rawmaterials
Process

Process

Process

B

A

Products Mixing of wastewater makes
the treatment difficult andD
increases the cost of treatments
Effluent
Primary Secondary Advanced

ProcessC

Mixed wastewater

Novel and advanced wastewater treatment and recycle system
Reduction in process water use
Rawmaterials

Process

Process

Process

Process

A

B

C

D

a'

b'

Similarwastewater

Productse

Simple and small
treatment isenough to meet theeffluent standard

Simple and 15 Effluent
advanced treatment

Supply and recycle system of ultra pure waterby onsite treatment in electronics industries
MF: micro-filtration
UF: ultra-filtration

Industrial water
well water

Pre-treatment
filtration

RO: Reverse Osmosis
Continuous Ion Exchange

Pure water

Rawmaterial

Cooling water
Boiler water
Primary
processWash& rinseMain
process

Ultra pure
water
Functional
water

Wash
& rinseLCD
Semi-conductor
Packagingrecycle water
Water
recovery

Products

Protection of Intellectual Properties
Wastewater
treatment

Huge ultra pure and functional water are used in the electronic industry, while the mostis recycled after sequential treatment. A little water is needed for the process operation.
16

Improvement of production process(1)Essential information and data for the improvement

Material flow analysis on industrial process

Material flow analysis on the process will give the information on:
raw material, reactants, products, inert, by-products, intermediates, etc.

Amount and composition of wastes and wastewater can be clarified
1)Improvement :conversion, yield, productivity, quality, etc.
2)Reduction : discharge of wastes and wastewater, energy consumption
17

Improvement of production process(2)Characteristics of wastewaters from industrial process

Pollutants discharge from automobile manufacturing plant

Oil &
SS(g)
Grease(g)Engine,Chassis Machining
20 - 200
145
100 - 70080
10 - 400
100 Body
Painting
1230 - 4100 300 - 900400 - 700 24 - 85
400
Brake
Forging & Painting 30 - 390 0.14 - 6.7
1.0 - 13.4
1.6 - 26.82 - 40
Electroplating
20 - 70
0.86
0.42
Transmission Casting
10 - 320
1 - 46
0.5 - 45
Products

Processing

Wastewater(l)

BOD(g)

COD(g)

18

Improvement of production process(3)Identification of problems in the existing process

System configuration and material flow in wastewater treatments of automobile factory
Unit process wastewaters
Machining
Casting
Forging

OthersRainfall, etc＊

72m3/d743mg/L
36m3/d2309mg/L
16m3/d3227mg/L
1955m3/d
90mg/L
41m3/dKitchen and toilet
wastewaters
235m3/d
66.8mg/L Mixing

2120m3/d Oil-water Coagulation＊
Floatation
171mg/L separation(1.06)High COD loading to AC adsorption
High operating cost of AC adsorption
Refractory chemicals (pollutants)
remain in the wastewater

Effluent

2355m3/d Activated

BOD<5mg/L

69.5mg/L(1.03)

COD:8.4mg/L(0.595)

ActivatedSandsludge 37.9 filtration 35.5mg/L carbon(AC)adsorption
mg/L(BOD/CODMn)
COD is CODMn(0.26)

Effluent quality standard applied
COD<10 mg/L in average
COD<15 mg/L in maximum
19 valueImprovement of production process(4)Identification of pollutants to be removed

Analysis of molecular size distribution and biodegradability of pollutants
contained in wastewater.
(MW)

50

5

1

Eluent : Water
Flow rate: 1 ml/ min
Column: MCI GEL CQP10
Injection volume: 20 µl

40

DOC (mg/ｌ）

10

0.5

0.1

x103

Removed bybiological treatment

1)It was due to the continuous
leakage of hydraulic oil fromhydraulic cylinders to operatemachining tool.

MW=25030

20Pollutants remained in theeffluent of biological treatment

10

MW=7000( BOD/DOC=0)

Why the pollutant with
MW=7000 exists in thewastewater from machining
process?

Influent
wastewater2）Principal ingredient of nonmineral hydraulic oil waspolyethylene glycol(PEG).

Effluent
Refractory chemicals
0
5

10

15
20
Elution Time (min)This material should be removed from the raw
and auxiliary materials in the production process

25

BOD/COD ratio: Biodegradability
20

Improvement of production process(5)Characterization of pollutants to be removed

Selection of applicable wastewater treatments for organic pollutants
based on molecular size and biodegradability

Bio-degradability(BOD/ThOD)

1.0

0.8

ThOD:Theoretical Oxygen Demands

Coagulation with
Sedimentation or
Flotation

Biological Treatment

0.6

Membrane
Filtration

0.4
Adsorption by
activated carbon
0.2

Chemicaloxidation?

0
10

2

3
10
Molecular Size (MW)

10

4

10

5

21

Procedure to determine appropriate
treatment of organic pollutants
Evaluation of pollutants in terms of coagulation, filtration,
biodegradation, chemical oxidation, adsorption.
Raw Materials, Process Wastewater
Coagulation or gravitational separation
No
Filtration, Membrane separation(flux, fouling, energy, life)
Yes
No
Effluent quality

Biodegradability and bio-treatablity test
BOD/TOC, BOD/ThOD, BOD/COD> x Good for biological treatment< y Not good for bio-treatments

Yes

Yes

No
Organic removal
Improvement of
biodegradability

Bio-degradability

No

Yes
Effluent quality

ChemicaloxidationNo

Yes
Effluent quality

Reduce utilization

Yes

No

Yes

No
Activated carbon adsorption, etc.

Effluent (recycle, discharge) 22

Procedure to evaluate the physico-chemical
technologies for suspended solids removal
wastewater
Size

ScreenQuality

Specific
gravity

Sedimentation

Ｙｅｓ

Floatation

Quality

Centrifuge

P. floatation

Quality

Polarity
Molecular
size

Ｙｅｓ

Ｙｅｓ

pH control＋coagulation
Quality

Filtration
QualityＹｅｓ

Ｙｅｓ

Next stage treatment

23
EffluentEnergy consumption in activated sludge processSandseparation
sewage下水 スクリーン
沈砂池

Secondarysedimentation Distankinfection
最終沈殿池
塩素滅菌槽
放流

Primary
aeration
sedimentation
tank
tank
最初沈殿池
エアレーションタンク

screen生汚泥

sludge汚泥消化
濃縮treatment

返送汚泥

recycle
再利用

空気

余剰汚泥

ポンプ

脱水機
脱離液
脱水ケーキ 焼却炉

高度処理
Advancedtreatment

焼却灰
埋立て

sludgeincineration

Activated sludge process for wastewater treatment
24

Improvement of production process(6)Experience in polymer production for wastewater reduction

Countermeasures in polymer production process to reduce wastewater
discharge by enhanced recycle of recovered effluent from each unit
process and by increase of polymer concentration in the reactor.
Month & Year

Jan. 1965

Jan 1973

Nov. 1973

Feb. 1974

Wastewater(m3/t-polymer)

36.2

17.0

8.8

0.2

Counter
measure

(A)

(B)

(C)
Production rate ofpolymer in the reactor
was increased(A) Increase the polymer concentration in the reactor,(B) Wastewater recycle from polymer separation process,(C) Wastewater recycle from catalyst washing and polymer drying processes.

25

Improvement of production process(7)Reduction in water use and pollutants discharge
This figure shows the transition in water use and pollutants discharge in pulp industry.

Production
Water use
Water use/Production
BOD discharge
COD discharge
SS discharge
0

100

200
Relative value to '75

Wastewater Discharge from Paper and Pulp Mills

26

300

Improvement of production process(8)Reduction of water use in production processThis figure shows the transition of process water use for ¥1 million($10,000) production in various industries. Water use was sharply
decreased around 1973!
Energy crisis@1973

Energy crisis@1973

27

Improvement of production process(9)Increase of water recycle ratio in industrial production
This figure shows the increase in used water recovery for recycle inindustry. The energy crisis in 1973 and 1978 triggered the increase ofrecycle ratio of recovered effluent after appropriate treatment.
Energy crisis@1973

Energy crisis@1973

28

Improvement of production process(10)Use of water and recycle in industries of Japan(×108m3/y）

Water recovery and recycle use

Water use for industry

Recycle ratio

Recycled water

Low contaminated effluent was preferentiallyrecycled after simple treatment.
Fresh water Intake

29

Improvement of production process(11)COD loading into closed sea area in Japan

Figure shows the transition in reduction of COD loading into
closed sea area in Japan.

Pollutionload(t/d)
発生汚濁負荷量(t/日)

2000

663
(37.0)

Pollution load
数値：上段(t/日)
upper (t/d)
下段(％)
lower
(%)
551
(34.5)

529(36.1)

437(34.3)

429(35.6)
産業系

Industrial

1000
961
(53.5)

0883(55.2)

783(53.5)

696(54.7)

637(52.8) 生活系
138(11.6) その他

170
(9.5)

164
(10.3)

152(10.4)

140(11.0)

79

84

89
西暦年度

94

Domestic

Others

99

Year

30

Improvement of production process(12)Top priority for the sustainable water use in development

Top priority for the sustainable water use in development is the
improvement of the production process
1)Analyze materials & energy flow in industrial production
process for diagnosis and to clarify the appropriate
countermeasure.

2)Before considering the treatment of wastes and wastewater,
improve the industrial process to minimize emission.
3)Select appropriate treatment technology and process basedon characterization of wastes and wastewater, and thenrecycle after treatment.

31

Improvement of production process(13)Management system for the stock and flow of chemicals
Application for the permission to purchase materials
Permission to purchase
Report on materials:
purchase & consume

Environment
Management HQ

Factory for
Industrial Production

Supplymaterials

Information of materials

SupplierRaw materials,
secondary materials
Secondary materials: paint, lubricant,coolant, detergents, hydraulic fluid, etc.

Database of materials used in
production process in termsof stock and flow

Environment management division canestimate the followings based on theinformation in the above:1)Composition of wastewater and the amountfrom the plant,2)Appropriate treatment method for thewastewater,3)Approach how to reduce the environment
loading and the impact from the production
process32

Application of Material Flow Analysis
MFA in plantation for appropriate use of biomass residues
Material flow analyses of biomass, biomass residue and wastewater inplantation of palm oil and cassava for sustainable cultivation of crops.

Palm oil mill (North Sumatra)

Tapioca mill (Lampung)33

Application of material flow analysis
Organic carbon flow in tapioca mill

Tapioca millCassava
140 t-C/d

40%

100%

(weight 700-750 t-wet/d)

Tapioca
56 t-C/d(weight 140-150t/d)

Cassava yield:13t/ha

26~40%
water
2,630 m3/d
oil
6,750 ℓ/d
electricity
34.5MWh/dSkin, tips
10~14 t-C/d

20~22%
3

wastewater Flow：3,000 m /d
28~30 t-C/d COD:18,000~25,500(mg/ℓ)

Onggkok
26~42 t-C/dMethane gas

Lagoon34

Application of material flow analysis
Organic carbon and nitrogen flow in tapioca mill

Carbon and Nitrogen flow in tapioca mill for 1 ton
cassava processing (wet base)

1 t-cassava(164 kg-C)(1.26 kg-N)

washing & peelingcrashing
separation

process
water
処理水
2.2m3

wastewater
2.4 m3(46.7 kg-C)(0.43 kg-N)

tapioca
タピオカ
204 kg(71.6 kg-C)(0.15 kg-N)
residue(108 kg-C)(1.34 kg-N)

Elot
Skin & tip
Onggok
8.1 kg
12 kg
102 kg(1.0 kg-C) (4.4 kg-C) (40 kg-C)(0.02 kg-N) (0.11 kg-N) (0.4 kg-N)
35

Application of material flow analysis
Wet weight base material flow in palm oil mill

Products:9.66t/h
Palm oil: 8.72t/h
Kernel oil:0.94t/h

FFB：40t/h
COD：31000g/m3
Steamelectricity

Fiber(moist.)
4.9t/hShell(dry)2.0t/hBoilerWastewater
400kg-C/h

Shell(moist.)
0.24t/hKernel shell
2.6t/hFlow：33.7m3/h
GHGemissionEFB
8.6t/hFor effectiveuse

Lagoon36

36

Application of material flow analysis
Organic carbon flow in a palm oil mill (POM)

Raw material
FFB
307 kg-C(1,000 kg)
For POM
operation

Steam
Electricity

BoilerShell 13kg-C
Fiber 38kg-C

Products
POM

100%

34.4%

63.4%

CPO
163 kg-C(215 kg)

PK
32 kg-C(43.0kg)

2.2%

Biomass residue

POME

EFB
38 kg-C (250kg)

7 kg-C(354kg)Fiber
44 kg-C (141kg)
Shell
24 kg-C(54kg)

BiogasCH4
42%

COD 50,000 mg/ℓ

100.0%

CO2
35%

CO2

77%
Effluent
9%

Lagoonsediment*
14%()moistened organic matter for FFB1,000kg

1)53 % of organic carbon in FFB is retained in CPO
2)77% of organic carbon flow into lagoon is biogas, 42%37
37 is methane.

Application of material flow analysis
Discharge of organic carbon from agro-industries

Organic carbon in wastewater[kg-C/ton]Amount of organic carbon discharge from agro-industries into wastewater per
one ton of products.

Tapioca(Cassava)

200

190~205

Palm oilCane sugar

per 1ton of raw material
per 1ton of product

100

38~41

42~45
9.2~9.8

0
Entire energy
from outside

0.3~0.6 3.5~7.1

No energy from outside

Huge organic carbon is discharged from tapioca mill into wastewater38

Application of material flow analysis
Carbon flow in palm oil mill lagoon
Inlet

Pond No.1

Pond No.2

Biogas 1.9ton-C/day

4.7t-C/day

Biogas 53%

Biogas 0.60t-C/day
0.60tonBiogasCH4 14%(35%)
CO2 26%(65%)-Flow rate
400m3/day-COD
31,550ppm

Pond No.3

40%

100%

13%

25%
8,000
COD8,000ppm
1.2t-C/day

35%

CH4 9%(67%)
CO2 4%(33%)

COD ?ppm

12%

edimentation
Sedimentation

1.5t-C/day
39

Application of material flow analysis
Carbon and nitrogen flow in cattle fattening

Carbon and Nitrogen flow in cattle fattening
using biomass residue of tapioca mill as feed
Biomass residue
Compression residue,
sediment, skin, etc.

4.3 kg/day(1.6 kg-C)(0.03 kg-N)

Fattening period
6 months

Breathing･burp
1.0 kg/day(0.3 kg-C)(0 kg-N)
ExcretaCompost4.4 kg/day
3.3 kg/day(1.8 kg-C) (1.2 kg-C/day)(0.08 kg-N) (0.09 kg-N/day)
Additional feed

Composting

Auxiliary feed Daily weight increaseCorn
1.1 kg/day 0.7 kg/day
0.4 kg/day
Rice husk(0.3 kg-C)(0.4 kg-C)(0.2 kg-C)
0.8 kg/day(0.04 kg-N) (0.03 kg-N)(0.02 kg-N)

40

Summary of this presentation
Categorization of industries
Kind ofproduction process

Kind of wastewater(characterization)
Process configuration
Input/output
Material flow

Improvement of production
Reduction of wastewater

Kind of treatments

Recycle use for what?

Appropriate selection andoperation of treatments

Impact on environment and ecosystem

Conditions of surrounding environments

41

Sustainable Water Use in Development of Asian Countries

City of Yokohama

Thank you for your kind attention！

42

Suspended solids removal fromindustrial wastewaters
Property of suspended solids

Process

Wastewater

Sedimentation

Starch, flour-milling
pulp & paper

1～103

low 1)>1

Floatation

Bean curd & its
deep-fried, rubber-

low 2)<1

Pressurized
floatation

Pulp & paper
cleaning

-

low

<1
or =１

Centrifuge

Pig manure, paintproduction

10-1～102

low 1)-

Coagulation

Food, electro-plating

10-3～1--

Filtration

Food, electro-plating

10-3～10low 5)

independentsize(μm) polarity

2)

Specific
gravity43