PROCESS DESCRIPTION

Client: Coca Cola FEMSA Philippines, Inc.

Prepared Date:
Proposed Upgrading of WWTP (180 CMH); existing 130 January 22, 2016
Project Title:
CMH, additional 50 CMH
Misamis Oriental Plant, Brgy. Katipunan, Villanueva,
Location: Revision No: 00
Misamis Oriental

Page 1 of 32
 PROCESS DESCRIPTION

INTRODUCTION:

The existing WWTP of Coca Cola needs to be upgraded in order to expand and
accommodate the additional loading capacity of the plant to better comply to the
effluent quality standards set by the DENR before discharge to the nearest body
of water.

Page 2 of 32
 PROCESS DESCRIPTION

Based from the technical data provided to us, our company is able to have a
comprehensive design and re-engineered the existing treatment plant with the
objective of optimizing the utilization of the existing equipment and structures to
attain the most possible lowest cost for the proposed treatment plant but not
compromising the technical considerations required.

The proposed upgrading of treatment system has the following stages of

treatment process.

Page 3 of 32
 PROCESS DESCRIPTION

a.) Pre-treatment by screening (Static Screen)

b.) Chemical treatment (for pH Adjustment before Biological Treatment)

c.) Bauer Dynamic SBR as biological treatment (Proposed)

d.) Aerobic Sludge Digestion (upto 50% digestion)

Page 4 of 32
 PROCESS DESCRIPTION

e.) Dewatering System using a Screwpress to produce a 20% dryness of sludge

cake (Proposed)

f.) Chlorine Disinfection (Proposed)

PRELIMINARY TREATMENT:

Page 5 of 32
 PROCESS DESCRIPTION

The existing capacity of the is 45 m3/hr for Phase 1 and 85 m3/hr for phase 2 with
a total capacity of 130 m3/hr. To meet the requirement of the plant, 50 m3/hr
treatment unit will be added to treat a total of 180 m3/hr.

The wastewater generated from the manufacturing plant is conveyed by gravity to

the Wastewater Treatment Plant and will be received in the raw wastewater sump.
The raw wastewater sump is equipped with three (3) existing submersible pump.

Page 6 of 32
 PROCESS DESCRIPTION

To cater the additional flow capacity, one (1) unit of submersible pump of same
capacity (65 m3/hr) will be added. The raw wastewater sump now have four (4)
submersible pump operating at 3-duty-1-standby (3D + 1S) basis. These pumps
are provided to transfer the raw wastewater to the subsequent treatment.

Prior to equalization tank, the wastewater will undergo screening and oil removal.
It will pass through existing automatic bar screen and the additional capacity will
pass to the proposed static screen. Static screen is the curve stainless wedge wire

Page 7 of 32
 PROCESS DESCRIPTION

hydrostatic screen used for solid-liquid separation. The specially designed non-
clog hydrostatic screen, with great opening area, offers an economical separation
process with more hydraulic capacity, higher efficiency and needs low
maintenance. Static Screen head box reduces turbulence of wastewater and
delivers flow to the wire. A swing baffle distributes flow across the width of the
screen surface and passes across the upper part of the screen panel. Most of the
solids are captured on the curved face of the screen while the liquid is drained to
the bottom part via the back of the screen. This screen provides excellent

Page 8 of 32
 PROCESS DESCRIPTION

liquid/solid separation at a low capital cost and low maintenance. Screening of raw
wastewater is done to prevent easy clogging of solids larger than 5mm such as
rags, paper, plastic, metals and the like that may damage the pump. The screened
solids will be dried and collected and will be placed in plastic bags to be
discharged together with the solid waste produced from the manufacturing plant.

The screened wastewater from the existing bar screens will then passed to the
existing oil and grease removal tank and then flow to the existing collecting /

Page 9 of 32
 PROCESS DESCRIPTION

equalization tank.

The screened wastewater from the static screen will flow directly to the
equalization tank since the oil and grease content is not that high and can be
removed through subsequent treatment. Since existing equalization tank is
calculated to be enough to handle the plant capacity at not less than 3 hours
retention time, therfore no additional equalization tank will be provided. Likewise,
the capacity of the existing equalization pumps are enough to pump the

Page 10 of 32
 PROCESS DESCRIPTION

wastewater to biological system.

The equalization tank is provided to handle the variable inflows of hydraulic

loading and the wastewater characteristics to make it homogenous/monolithic for
better result and efficiency of chemical treatment. The existing equalization tank
is equipped with submersible mixer to continuously mixed the wastewater to avoid
the possibility of septic activities or the formations of mal gases especially during

Page 11 of 32
 PROCESS DESCRIPTION

shutdown period of the manufacturing plant.

After equalization tank, flow will be pumped to biological treatment. The flow will
be divided according to the capacity of the biological treatment. 130 m3/hr will flow
to the existing SBR tank and 50 m3/hr will flow to the proposed Bauer Dynamic
SBR. Automatic modulating valve (motorized valve) will be provided to each
pipeline to control the flow. Ultrasonic non-contact flowmeter will also be provided
after each motorized valve to measure the flow coming in and it will signal the

Page 12 of 32
 PROCESS DESCRIPTION

motorized valve for control ang modulation of the opening of the valve.

Since the pH of the raw wastewater is too basic with a pH range of 11-12, pH
adjustment before going to biological treatment is necessary. The pH of the
environment has a profound effect on the rate of microbial growth. pH affects the
function of metabolic enzymes. Acidic conditions (low pH) or basic conditions
(high pH) alter the structure of the enzyme and stop growth. Most microorganisms

Page 13 of 32
 PROCESS DESCRIPTION

do well within a pH range of 6.5 to 8.5. Abnormal or irregular pH in biological

treatment processes can result in a significant decrease in the rate of removal of
organic compounds from the environment, which will affect the biochemical
oxygen demand (BOD) measurements.

The pH of the wastewater will be adjusted from 12 to 8.5. pH adjustment reaction

loop will be provided for enough reaction time and mixing of the chemical. Sulfuric

Page 14 of 32
 PROCESS DESCRIPTION

acid (H2SO4) with dosage of 300-500 ppm will be used to lower the pH to 8.5.
Standby Caustic dosing system will also be provided to balance the pH if
necessary. pH controller will be provided after the pH adjustment reaction loop to
measure the resulting pH after chemical addition and to signal the dosing pumps
for adjustments.

Page 15 of 32
 PROCESS DESCRIPTION

SECONDARY TREATMENT

The pretreated wastewater will now be treated in a biological treatment process

called Bauer Dynamic SBR. There will be an additional two (2) SBR basins to be
utilized. Each of the basins will be similar to each other in all aspects. In each of
the SBR system, the tanks are acting as the equivalent of several components in
a single tank such as Aeration, Settling and Decanting system. There will be six
cycle of SBR process per day, each cycle takes 4 hours to complete; 2 hours

Page 16 of 32
 PROCESS DESCRIPTION

aeration, 1 hour settling and 1 hour decant. While basin 1 is settling and
decanting, the other basin will be aerating and so on.

The wastewater will be equally fed continuously into the pre-aeration chambers of
the three SBR basin and is directed down through an engineered orifice opening
at the bottom of the baffle wall into the main aeration. The pre-react wall controls
the incoming flow and prevents short-circuiting and provides the pre-treatment of

Page 17 of 32
 PROCESS DESCRIPTION

the waste water before it enters the main react zone. This is due to the continuous
influent flows into the pre-react zone where a high concentration of soluble BOD is
available to microorganisms in a relatively small basin volume which creates a
high “Food to Microorganisms” (F:M) ratio and encourages the maximum
biosorption of food by the microorganisms. The FM ration used in this design is
0.95 day-1. This also acts as a biological selector encouraging the proliferation of
the most desirable organisms and eliminates the growth of filamentous bacteria
that cause sludge bulking and poor settling.

Page 18 of 32
 PROCESS DESCRIPTION

The main react and pre-react zone has a complete air distribution system using
EPDM Fine bubble Diffusers coated with PTFE (Teflon). The PTFE coated EPDM
diffuser required no cleaning, anticipated life cycle cost benefits and reduced
maintenance. They are considered high performance due to their broad spectrum
resistance to chemicals, solvents, fats, greases, etc., which can damage
conventional elastomers. Air is supplied from the three-lobe type air blowers (1-

Page 19 of 32
 PROCESS DESCRIPTION

duty-1-standby) through these diffusers to be installed equidistant at the bottom of

the tank. The blower system is designed to provide sufficient airflow to meet the
system process requirements. Dissolved oxygen (DO) is added to the aeration
basin to enhance the oxidation process by providing oxygen to aerobic
microorganisms so they can successfully turn organic wastes into inorganic
byproducts. However, when the DO levels become too high, energy is wasted,
expensive aeration equipment undergoes unnecessary usage, and unwanted
organisms (filamentous biology) are promoted. Power costs associated with the

Page 20 of 32
 PROCESS DESCRIPTION

operation generally run from 30 to 60 percent of the total electrical power used by
a wastewater treatment facility therefore equipping the aeration basin with on-line
DO measurement (DO meter) automates the aeration system to maintain the
correct amount of DO. DO meter will be provided on each of the SBR basin and
will be integrated to the control panel. The blower will be allowed to operate during
aeration phase to mix and oxygenate the wastewater to produce biomass or
sludge. The blower stops after completion of the aeration time and the biomass
formed are allowed to settle to the bottom of the basin leaving a layer of clear

Page 21 of 32
 PROCESS DESCRIPTION

water on top based on the programmed period of time.

The uppermost clear water is discharged from the top of the basin while the basin
is continuously receiving the influent using a rugged, corrosion resistant stainless
steel floating type decanter located on the basin center end opposite from the pre-
react zone.

The decanter is parked on the top water level (TWL) during the aeration and

Page 22 of 32
 PROCESS DESCRIPTION

settling phases of the cycle, a scum / sludge exclusion installed to eliminate any
possibility of solids/biomass carryover during these periods and also allow an easy
access and service without the need to enter the basin. The floating decanter is
always under pressure both during aeration and settling as well as 3-5 minutes
before decanting to assure that no solids will carry-over with the treated water.

After the five (5) minutes time, the decanter motorized valve open to continuously
discharge the effluent to the chlorine contact tank while the air solenoid valve from

Page 23 of 32
 PROCESS DESCRIPTION

the air flush line will closed. Excess sludge will be removed using non-clog
submersible pump during decant phase to maintain the appropriate MLSS (mg/L)
of 5765.09 mg/L. The amount of biomass present in the system can be checked
by getting the Sludge Volume Index (SVI) which is about 150ml/L at 30 minutes.
The sludge waste pump run can be adjusted to obtain the average MLSS of
5765.09 mg/L and MCRT of 14.56 days by adjusting the time of run at the Human
Machine Interface (HMI) mounted on the control panel.

Page 24 of 32
 PROCESS DESCRIPTION

The treatment process will be controlled by reliable PLC computer controls

(Siemens), programmed to suit the requirements of the process. Since the plant
will be automated, daily operation demand is minimal. Operators need only
perform routine house cleaning, equipment maintenance, organize the sludge
removal and manage the site facilities.

The whole system is “time-based” operated and controlled using a programmable

logic controller (PLC) and SCADA. The control system consists of a control panel

Page 25 of 32
 PROCESS DESCRIPTION

including a human machine Interface (HMI), programmable logic controller, control

switches, pilot lights and motor starters. The SCADA will be provided to control
the whole operation of the plant and the proposed equipments as well as the
existing equipment will be integrated to the system. The control panel is factory
tested prior to shipment. During the start up of the Bauer Dynamic SBR, our
authorized field representative will check the operation and make necessary field
settings and program adjustments. After the system has been placed into the
service, there are minimal adjustments required by the operator such as sludge

Page 26 of 32
 PROCESS DESCRIPTION

pump start and wasting times and blower adjustments. The SBR system shall
have a sequence of operations of normal cycle at dry-weatherflow and storm cycle
at wet weather flow.

CHLORINE DISINFECTION SYSTEM

The decanted wastewater from the SBR basins will be disinfected at the existing

Page 27 of 32
 PROCESS DESCRIPTION

Effluent tank. The chlorine shall destroy the disease-causing microorganisms. The
liquid chlorine (Sodium Hypochlorite, 7% conc) with an appropriate dosage of 3.5
mg/L will be fed automatically and mixed with the effluent of the SBR basins.

Generally, a chlorine residual of 0.5 mg/L after contact time indicates effective
disinfections. The chlorine dosing system shall be operated automatically by
synchronizing with the decanter operations. Treated effluent from the Effluent tank
will be discharge to the storm drainage or nearest body.

Page 28 of 32
 PROCESS DESCRIPTION

SLUDGE TREATMENT AND DEWATERING SYSTEM

The sludge produced from Bauer Dynamic SBR will be collected at the proposed
aerobic sludge digester. Waste sludge will be stored and treated by means of
biological process called Aerobic Digestion. Aerobic digestion is a method of
sludge stabilization wherein biodegradable organic matter decomposed at about

Page 29 of 32
 PROCESS DESCRIPTION

70 – 80% reduction into a relative stable compound and oxidized some cellular
material into CO2, H2O, and NO3. This process is possible by continuous mixing
and oxygenation using a blower and stainless steel bubble diffusers. The total
sludge produced from the secondary treatment is calculated to be 982.8 kg/day
and estimated to have atleast 50% reduction on the sludge digester. The digested
sludged is estimated to be 491.4 kg/day.

The stable sludge will be further treated at the dewatering facility . It will then pass

Page 30 of 32
 PROCESS DESCRIPTION

through the screw press to convert the sludge to dry sludge cake with a 20%
dryness. Inorder to achieve this, polymer is injected at a dosage of 2.5 g per kg of
solids to aid in the dewatering process. The feeding of the stock solution of the
polymer is automatic by a diaphragm type dosing system. The calculated volume
of sludge after dewatering will be 2.46 m3/day. This dry sludge cake produced can
be used as organic fertilizer due to high nitrogen content of the wastewater or can
also be disposed as landfill.

Page 31 of 32
 PROCESS DESCRIPTION

For further technical reference for the whole treatment process, please find
attached STP process flow diagram.

Page 32 of 32