1.0 INTRODUCTION

This manual contains all information for operating and maintaining the wastewater treatment plant at Preferences Trading Industries Sdn Bhd.

The wastewater treatment plant is designed to provide an optimal pollutant removal. This can only be reached when the instruction given in this manual are taken care off. For detailed information concerning the equipment installed, please refer to the relevant chapters/catalogue.

This manual also contains instruction about equipment routine inspection, analysis of certain parameters on varied time intervals and to maintain a proper record of these. To meet the required effluent quality, it is absolute important that these data are controlled and recorded.

1.1 DESIGN CRITERIA

1. Source of effluent : E-Waste

2. Design Capacity : 3.93 m3/Hr

3. Operating Hours : 8 hrs/day

4. Treated Water Requirement

DOE Std BPH 5.5 – 9Cyanide < 0.1 ppmLead < 0.5 ppmSuspended Solid < 100 ppmOil & Grease < 10 ppmCOD < 100 ppmBOD < 50 ppm

5. Treatment Method.This is the combination of cyanide destruction treatment system and continuous chemical precipitation treatment system. The pH of the waste water is adjusted with acid and caustic and the pollutants are removed by adding various type of coagulants and flocculating agents. The sludge is removed through filter press.

2.0 EQUIPMENT SPECIFICATIONS

1. CN HOLDING TANKCapacity : 10 m3Material : FRPQuantity : 2

2. CN DESTRUCTION TANKCapacity : 2.5 m3 Material : FRPQuantity : 2

3. EQUALIZATION TANKCapacity : 15 m3 Material : FRPQuantity : 1

4. CHEMICAL REACTION TANKCapacity : 3.5 m3 Material : FRPQuantity : 1

5. CHEMICAL TANKCapacity : 250 LiterMaterial : FRPQuantity : 3

6. CHEMICAL TANKCapacity : 500 LiterMaterial : FRPQuantity : 2

7. CLARIFIERCapacity : 2 m3Material : FRPQuantity : 1

8. FINAL PH ADJUSTMENT TANKCapacity : 1 m3 Material : FRPQuantity : 1

9. BREAK TANKCapacity : 1 m3 Material : FRP

Quantity : 110. SLUDGE THICKENER TANK

Capacity : 1 m3 (Conical Bottom) Material : FRPQuantity : 1

11. CN TRANSFER PUMPSuper Magnetic Sealless PumpModel : SMF 25180-3 C/w 0.18kw, 3ph/415V/50Hz motorMaterial : FRPPCapacity : 2 m3/hr@5.5 mInlet/Outlet : 1”Quantity : 4

12. CHEMICAL TREATMENT FEED PUMPEbara Stainless Steel Centrifugal PumpModel : CDX 70/05 C/w 3ph/415V/50Hz motorMaterial : Stainless steelCapacity : 4 m3/hr@6 mInlet/Outlet : 1.25”Quantity : 2

13. CHEMICAL DOSING PUMPModel : Husky 205-D12096Material : PP Wetted Parts & Santoprene DiapharagmPort Size : ¼” X ¼”Quantity : 9

14. DESLUDGE PUMPModel : Husky 1590-DBCGGGMaterial : Aluminium Wetted Parts, Geolast Ball & DiapharagmPort Size : 11/2” X 11/2”Quantity : 1

15. FILTER PRESS FEED PUMPModel : Husky 1590-DBCGGGMaterial : Aluminium Wetted Parts, Geolast Ball & DiapharagmPort Size : 11/2” X 11/2”Quantity : 1

16. CARBON FILTER FEED PUMPEbara Submersible PumpModel : Best 1 SGC/w 0.25kw, 1ph/220V/50Hz motorMaterial : Stainless Steel 304Quantity : 2

17. DRY PIT PUMPEbara Submersible PumpModel : Best 1 SGC/w 0.25kw, 1ph/220V/50Hz motorMaterial : Stainless Steel 304Quantity : 1

18. CN DESTRUCTION TANK MIXER3 ph/415V/50Hz motorStainless steel shaft & PropellerOutput Speed : 900 rpmQuantity : 2

19. CHEMICAL REACTION TANK MIXER3 ph/415V/50Hz motorStainless steel shaft & PropellerOutput Speed : 900 rpmQuantity : 2

20. CHEMICAL REACTION TANK MIXER3 ph/415V/50Hz motorStainless steel shaft & PropellerOutput Speed : 120 rpmQuantity : 1

21. TFLOC TANK MIXER3 ph/415V/50Hz motorStainless steel shaft & PropellerOutput Speed : 120 rpmQuantity : 1

22. AIR BLOWER Taiko Roots BlowerModel : SSR50C/w 2.2kw, 3ph/415V/50Hz motorCapacity : 1 m3/min@ 4 m Head Quantity : 1

23. FILTER PRESSBrand : Well Filter Press Press Type : 500 mm X 500 mm X 17 chambers X 32 mm (Manual)Model No : KP50C104/MOL5 (Manual)Press Volume : 104 litersQuantity : 1

24. PH CONTROLLERModel : D1C - pHSignal Input : mV from sensorResolution : 0.01 pHPower : 230V, 50Hz, 0.05AMeasuring Range : 0 – 14 pHQuantity : 5

25. ORP CONTROLLERModel : D1C – ORPSignal Input : mV from sensorResolution : 1 mVPower : 230V, 50Hz, 0.05AMeasuring Range : 0 – 1000 mVQuantity : 2

26. DISCHARGE FLOWMETERBrand : BurkertModel : 8046Supply : 24VDCQuantity : 1

27. CARBON FILTERCapacity : 3.3 cuftQuantity : 3

3.0 OPERATION METHOD

3.0 CYANIDE DESTRUCTION PACKAGE

3.0.1 Function

This process involves the addition of Oxidising agents and chemicals to oxidize cyanide into cyanate and ultimately to carbon dioxide and nitrogen.

Destruction of cyanide by chlorination may be accomplished by direct addition of oxidizing agents exp. Sodium hypochlorite plus sodium hydroxide to the waste water. The hypochlorite added or produced oxidizes cyanide to cyanate. Oxidation of cyanide to cyanate is accomplished most completely and rapidly under alkaline conditions at pH 10.5 or higher, and this cyanide treatment process is often termed alkaline chlorination. At the same time, Oxidising agent is added until ORP becomes more positive than about +300 mV. An oxidation period of 30 minutes to 2 hours is usually allowed. To avoid solid cyanide precipitates which may resist chlorination, the waste water should be continuously mixed during treatment.

3.0.2 Operation

Make sure that the pH & ORP Controller, pH-1 pH-2 and ORP –1, ORP-2 are functioning.

Make sure all Chemical Tank (TOxid, TALK) have sufficient chemicals for operation.

Switch all of the relevant dosing pumps to ‘AUTO’.

Switch all the relevant mixers (MX-1, MX-2) to ‘ON’ position.

Select CN Transfer Pump to be operated by switching selector switch of the selected pump to ‘ON’ position.

Ensure the Inlet and Outlet Valve of the selected pump is open.

The pump is interlocked with Level Switch in the CN Holding tank. The Level Switch is actuated by the water level in the tank to repeat the pump ‘ON’ signal at high level and pump ‘OFF’ at low level automatically.

Make sure that all mixers are operating.

The control of dosing pumps may change to manual instead of auto depending on the wastewater condition.

Weekly counter changing of transfer pump operation is recommended.

3.0.3 CHEMICAL PREPARATION

1. T OXID – 100 % CHEMICAL

2. TALK - 20 % CHEMICAL + 80 % WATER

3.0.4 Maintenance

For the maintenance of Dosing Pump and flow meter, please refer to the individual manuals.

3.1 CHEMICAL PRECIPITATION PACKAGE

3.1.1 Function

This process involves the addition of chemicals to alter the physical state of dissolved and suspended solids and to facilitate their removal by sedimentation.

Coagulation and Flocculation is a process, in which chemicals which promote the aggregation of suspended/ dissolved solids into particles large enough to be separated by sedimentation. The effectiveness of a particular coagulant varies in different applications, and in a different application every coagulant has an optimum concentration and pH range in this process.

For full effectiveness, wastewater requires initial rapid mixing to disperse thoroughly the applied chemicals so that they can react with suspended and colloidal solid uniformly.

Inclined Plate in the settler is useful in prevent/ minimize carry over of lighter floc. By installing the inclined plate in the settler, suspended solids will be settled more rapidly to the bottom of the tank, than in an open channel flow system (clarifier without inclined plate). This is because the inclined plate providing more contact surface for the adherence of particles and hence separate the particles from the carrier flows. These particles will be then settled to the tank bottom by gravitational force and forms a layer of sludge, which will be than pump to Dewatering Package.

3.1.2 Operation

Make sure that the pH Controller, pH-3 pH-4 and pH-5 are functioning.

Make sure all Chemical Tank (TAD, TA 10, TALK, TFLOC) have sufficient chemicals for operation.

Switch all of the relevant dosing pumps to ‘AUTO’.

Switch all the relevant mixers (MX-3, MX-4, MX-5, MX-6, MX-7) to ‘ON’ position.

Select EQ Feed Pump to be operated by switching selector switch of the selected pump to ‘ON’ position.

Ensure the Inlet and Outlet Valve of the selected pump is open.

The pump is interlocked with Level Switch in the Equlization tank. The Level Switch is actuated by the water level in the tank to repeat the pump ‘ON’ signal at high level and pump ‘OFF’ at low level automatically.

When the tank is in high level, Level Switch will trigger the high level alarm and switch ‘ON’ the Feed Pump. All mixers and dosing pump in this package will automatically ‘ON’ and operated according to the pre-set value.

Make sure that all mixers are operating.

The control of dosing pumps may change to manual instead of auto depending on the wastewater condition.

Weekly counter changing of transfer pump operation is recommended.

3.1.3 CHEMICAL PREPARATION

3. TAD – 20 % CHEMICAL + 80 % WATER

4. TA10 – 100% CHEMICAL

5. TALK - 20 % CHEMICAL + 80 % WATER

6. TFLOC – APPR0X 70 g OF CHEMICAL POWDER + WATER.

3.1.4 Maintenance

For the maintenance of Dosing Pump and flow meter, please refer to the individual manuals.

3.2 SLUDGE DEHYDRATION

3.2.1 Function

The purpose of having a Sludge Thickener after the clarifier is to further concentrate the solids and thereby reduce the disposal and handling cost of sludge. The sludge will be settled by gravitation force in Sludge Thickener and is then pumped to the Filter Press by Filter Press Feed Pump.

In Filter Press, dewatering is achieved by forcing the water from the sludge under high pressure. The filter press consists of a series of rectangular plates, recessed on both sides, that are supported face to face in a vertical position on a frame with a fixed and movable head. A filter cloth is hung or fitted over each plate. The plates are held together with sufficient force to seal them so as to withstand the pressure during the filtration process. Hydraulic rams are used to hold the plates together.

Sludge is pumped to the space between the plates and pressure is applied to force the liquid through the filter cloth and plate outlet port. The plates are then separated and the sludge is removed. The filtrate is returned to the equalization sump and the dried sludge will be collected in sealed container for final disposal.

3.2.2 Operation Method

In a fix interval period, or when sludge is needed to be pumped out from the Sludge Thickener. Manually turn the Filter Press Feed Pump to ‘ON’ position.

Pressure will slowly increase when the filter press is filling up with sludge. Eventually the pressure will be built up to a limit where the diaphragm pump is unable to run. Manually turn ‘OFF’ the switch when the Filter Press is full.

Proceed to remove the sludge cake from the filter plates.

3.2.3 Maintenance

The cloth of Filter Press must be clean with Water Spray Gun periodically.

3.4 CARBON FILTER

3.4.1 Introduction

The purpose of Carbon Filter is to remove Chlorine and Organic Impurities from the water. Although the filter also accomplishes filtering of turbidity, it is incidental to the prime purpose of the filter. Greater amount of turbidity in the inlet water can decrease the effectiveness of the carbon, shortening its useful life. Other types of filters upstream of the Carbon Filter should remove turbidity.

3.4.2 Initial Start-Up

New Activated Carbon is recommended to be soaked for at least 24 hours before backwashing. During initial start-up Carbon Filter shall be backwashed, until the backwash water is clean before putting to rinse and then service.

3.4.3 Operation

When the Filter is in operation, water enters the top of the Filter and is evenly distributed over the media bed. As it flows through the bed, chlorine and impurities are trapped at the top of the bed while organic are absorbed on the carbon granules throughout the entire bed. The differential pressure across the Carbon Filter bed is not a good indicator for the need to backwash. The Carbon Filter should be backwash every day to help keep it sterile.

Carbon Filter media does not have an unlimited life. Eventually the granules will no longer adsorb organic and chlorine to a useful degree. When this occurs, the carbon must be replaced. Generally, a carbon bed may be expected to be useful for approximately 6 to 12 months. High levels of chlorine and organic can reduce filter media life and low levels can increase the life. The best way to determine the condition of the carbon bed is to periodically check the filter effluent for excessive signs of chlorine and organic.

3.4.4 Backwashing of Carbon Filters

When performing the backwashing for the Carbon Filter, the following steps are taken: Interchange the inlet hose to outlet position and it with outlet hose to inlet

position. Ensure there is sufficient water in the Break Tank Ensure the discharge valve pipeline divert to EQ Tank Press the ON button to initiate the CF Pump. Check until the backwash water

is clear When the backwash is completed, Off the CF pump and change back the

Inlet/Outlet hose and valves back to normal position.

FOR THE MAINTENANCE OF DOSING PUMP AND FLOW METER, PLEASE

REFER TO THE INDIVIDUAL MANUALS

4.0 THEORY OF OPERATION

COAGULATION FEED THEORY AND OPERATION

Very small particles below 10 um in size cannot be separated simply by sedimentation because of their very slow settling velocities. The stability of these fine suspensions is due to electrostatic forces and it is necessary for these to be neutralized to encourage flocculation into assemblages of small particles which will precipitate more readily.

Coagulant are added to neutralize the charges on the particles which then agglomerate to form a floc with improved settling characteristics.

The floc mass is spongy and because of its large surface area, absorbs dissolved matter from solution; therefore it also assists in the removal of colour, turbidity, organic matter and bacteria from solution.

The selection of suitable coagulant, the correct dosage and the optimum pH for treatment depend upon several factors such as the effluent requiring treatment, its temperature and other limitations on discharge and also on the equipment available.

POLYMER FEED THEORY AND OPERATION

Polymers when dissolved in water containing finely coagulated particles will cause further agglomeration of suspended solids to form large flocs.

Because of the flocculation ability, the polymer when applied in the flocculation tank will speed up the sedimentation process i.e. the settling becomes faster in both the plate settler and in the sludge holding tank. It improves the thickening and dewatering process in the filter press process.

APPLICATION

Before carrying out the operation trials, it is advisable to determine the most suitable polymer for the job by laboratory jar tests. Specific features such as optimum dilution rate, amount of chemical dosage, the duration and intensity of stirring/mixing process are pre-determined. Multiple polymers if necessary can also be used.

PH ADJUSTMENT

PH treatment is basically concerned with acidic or alkaline treatment. Acid and alkaline are basically the converse of each other. When acid is neutralized with caustic, the Hydroxyl ion (high pH) of an alkali will treat the hydrogen ions of acids (low pH) to form water. The acid anion and the caustic cation will form a salt e.g. NaCl.

The choice of alkaline to be used for neutralization is dependent upon local conditions and the actual requirements of the alkaline. Lime is used for waste which required extension treatment, but lime preparation is inconvenience and sludge volume is large as compared to caustic soda which is relatively easy handle and it therefore recommend for low requirement.

5.0TROUBLESHOOTING

ITEMS TYPE OF PROBLEMS REMEDY1 No Floc - Check all the chemical pump is

working or not.- Chemical already prepared and dosing

in sequence.- Check the pH setting/reading is correct

or not, if pH reading is not correct, please perform calibration on the pH probe. Preferable perform calibration once a month. (Procedure refer catalogue)

2 Transfer Pumps not working

- Check the switch is On or not.- Level of the sump is too low- Check the pump float switch- Others refer pump catalodge

3 ORP & PH Controller Malfunctions

- Refer controller manual.

4 Filter Press Malfunctions - Refer operating manual5 Chemical Dosing Pump

Malfunctions- No air supply.- Purge out water in the air line.- Refer operating manual

6 Desludge Pump Malfunctions

- No air supply.- Purge out water in the air line.- Refer operating manual

7 Carbon Filter Blockage - Change the granular carbon inside the column. (Recommendation to change 3 –6 months depend on waste characteristics)

6.0 SAFETY PRECAUTIONS

6.1 PERSONAL SAFETY PRECAUTIONS

These summarized cautions and safety instruction should be communicated to all personnel working on and/or around the Wastewater Treatment Plant. Guidelines below should be supplemented with formal safety training in the safe handling of all chemicals. Appropriate safety equipment should be available.

6.1.1 Severe Personal Injury or Death May Occur

If in doubt, STOP and ask for help

NEVER add water to acid or mix strong acid with strong caustic. A violent reaction occurs

NEVER add water or acid to strong caustic. A violent reaction occurs.

NEVER reach into energized electrical panel. Electrocution may result

ALWAYS keep hands, loose clothing and long hair away from rotating machinery

6.2 CHEMICALS PRECAUTIONS

WARNING ALWAYS wear safety goggles and full face shields, use rubber gloves and wear chemical resistant aprons and boots when handling chemicals, charging tanks, checking chemicals feed connections, taking samples, etc.

WARNING ALWAYS be sure that pipe and tubing is depressurized before disassembly. When reassembling connections, ensure that all connections are tight. Re-pressurize slowly to avoid spills and leakage. Be especially careful around the metering pumps.

DANGER NEVER ADD WATER TO CONCENTRATED ACID OR MIX STRONG ACID DIRECTLY WITH CONCENTRATED CAUSTIC SODA.

A rather violent reaction will occur with the release of a great deal of heat. Such reaction could cause severe injury.

WARNING ALWAYS reads and follows instruction on the labels of chemical containers.

NEVER mix chemicals together without knowing what the result will be.

WARNING NEVER ADD WATER TO CAUSTIC SINCE EXCESSIVE HEAT WILL BE GENERATED. ALWAYS add caustic to water SLOWLY

WARNING NEVER ADD WATER TO ACID SINCE EXCESSIVE HEAT WILL BE GENERATED. ALWAYS add acid to water SLOWLY

6.3 ELECTRICAL PRECAUTIONS

DANGER ALWAYS makes sure that electrical power has been disconnected before any electrical panel or junction box. Electrical troubleshooting or repair should perform only by trained personnel.

6.4 MECHANICAL COMPONENTS PRECAUTIONS

DANGER ALWAYS keeps hands, loose clothing, long hair away from rotating shafts or pumps and mixers.

WARNING ALWAYS open and close valves slowly to avoid water hammer, which may cause damage to connections or equipment.

CAUTION ALWAYS makes sure that settings of liquid level floats are sufficient to avoid cavitation of the pumps.

7.0 DRAWINGS

8.0 EQUIPMENT MANUAL AND CATALOGUE

OPERATION MANUAL

3.92 m3/Hr CHEMICAL WASTE WATER TREATMENT

SYSTEM

FOR

PREFERENCES TRADING SDN BHD

BY

TERTIB ALAM ENTERPRISE