USTYURT GAS CHEMICAL COMPLEX

A87 WASTE WATER TREATMENT SYSTEM

 CONTENT:
1. SAFETY MOMENT
2. INTRODUCTION
3. UNITS OF U&O
4. WASTEWATER SEWERS OF UGCC
5. OILY AND SANITARY SEWERS COLLECTION
SYSTEMS
6. WASTE WATER TREATMENT PACKAGE (X-8701)
7. QUALITY OF TREATED WASTE WATER
8. DISPOSAL POND OF 2.1 MILLION CUBIC
METERS
9. OPTIMIZATION MEASURES OF WASTE WATER
TREATMENT PACKAGE
10. CONCLUSION
SAFETY MOMENT
 INTRODUCTION
The construction of the Ustyurt Gas
Chemical Complex (UGCC) was
completed in September of 2015,
within 3 years and 3 month earlier
than scheduled date.
The complex consists of 5 main plants:
1. Gas separation plant;
2. Ethylene production plant;
3. Polyethylene production plant;
4. Polypropylene production plant;
5. Utility and Offsities plant.
 UNITS OF UTILITY AND
OFFSITIES PLANT
• A81 - RAW WATER, POTABLE WATER
• AND SERVICE WATER SYSTEM
• A82 - COOLING WATER SYSTEM
• A83 - DEMINERALISED WATER AND BOILER FEED WATER SYSTEM
• A84 - STEAM GENERATION & DISTRIBUTION / CONDENSATE RECOVERY
SYSTEM
• A85 - AIR & NITROGEN SYSTEM
• A86 - FUEL OIL & FUEL GAS / BLOW DOWN & FLARE SYSTEM
• A87 - WASTE WATER / WASTE WATER REUSE SYSTEM
• A88 - ELECTRIC POWER GENERATION SYSTEM
• A91 - LPG/NGL FACILITIES
• A92 - ETHYLENE STORAGE FACILITIES
• A93 - PROPYLENE STORAGE FACILITIES
• A94 - OTHER HYDROCARBON FACILITIES
• A95 - FIRE WATER SYSTEM
• A96 - CHEMICAL STORAGE SYSTEM
 WASTEWATER SEWERS OF UGCC
The Waste Water Treatment Facility for the
Process and U&O areas of UGCC U&O Project is
based on collecting the various plant waste water
and routing them to the Waste Water Treatment
System(X-8701) in UTOS plant Uzbekistan.
Various process units produce waste water that
can be categorized as follows:
- Oily Wastewater and Potentially Contaminated
Surface Water
- Dilution Steam Blow down from Ethylene Plant
- Chemical or non-oily waste water
- Excess fire water
- Sanitary Waste Water
 Waste Water Treatment Package (X-8701)
The Waste Water Treatment Package (X-8701) with
135m3/hr (75m3/hr for CPI inlet and treated Waste
water 135m3/hr) of design capacity, the various
influent wastewaters from the UGCC complex via
wastewater collection and transfer system will be
treated to meet the specification of discharge.
The overall wastewater treatment package (X-8701)
consists of the following units;
- CPI (Corrugated Plate Interceptor)
- pH Control/coagulation/ flocculation
- DAF (Dissolved Air Flotation)
- Equalization basin
- Biological Treatment System
- Tertiary treatment (Sand filters and A/C filters)
- Sludge Treatment System
- UV Sterilization System
Waste water treatment package (X-8701) for the treatment of industrial and sanitary
effluents of the Ustyurt Gas Chemical Complex was built in accordance with a project of
HIORIM INDUSTRIS (South Korea) by general contractor HYUNDAI ENGENEERING Co.
(South Korea).
Unit was commissioned in 2015.
 WASTE WATER TREATMENT PACKAGE A87 (X-8701)
H2 SO4 PAC Coagulant
P16A/S P20A/S
NaOH A-polymer Sanitary WW
P17A/S P22A/S P-8711A/S
CAMP Sanitary WW Sanitary WW P-8708A/S
X-8702 UF drain water
Oily waste water
P-8704A/S LI
5 AI AI LI
0 LI
M M M M AI TI LI
1
X-8701-T01
SPLITTER BO X for CPI
tank X-8701-T04A/B
X-8701-T03
X-8701-T02A/B SPLITTER BO X DAF TANK
CPI TANK X-8701-S01 X-8701-S02 X-8701-S03 fo r DAF tank F-42 m3/hr
F-42 m3 /h pH CO NTROL CO AGUL ATIO N FLOCCULATION X-8701-S06
BASIN BASIN BASIN M M
M EQUA LIZATION BASIN
V-21.3 m3 V-21.3 m3 V-21.3 m3 P01A/B V-607.1 m3
DAF recycle pum p
LI
F-m3/h
Oily s lu dge X-8701-P05A/B/S
X-8701-S05
Scum s lu dge Bio system feed p ump
OIL Y SLU DG E SUMP
F-m3 /h
V-65 m3 Treated water
Bio slud ge
P04AS
Oily s lu dge feed p ump PI
F-m3 /h S18
S17
Bio dec anter
X-8701-P23B/S C-polymer Drain water THICKENER
feed b as in
D02 BASIN
CENTR IFUGE DECANTER fo r LI V-10.2 m3 P15AS
V-98.2 m3
Oil sludge Oily s lu dge Decant er feed pum p
5
F-m3/h
0

Pla nt a ir
9
90% V-01A/B
S-8601 X-8701-S15 X-8701-S16
80% DAF air d iss olving C-polymer
WW DRAIN SUMP SLUDGE BACK UP BASIN X-8701-P23A/S
P03AS 50% vessel V-1 m3
X-8701-S04 V-115.2 m3 V-599 m3
Slop oil t ran sfer pump SLOP O ILY PIT
F-m3/h P13AS P14AS
V-13.1 m3
Drain water tran sfer pump Bio slud ge tran sfer pump
F-m3 /h F-m3/h
D01
CENTR IFUGE DECANTER fo r Bio s lu dge

Inter. recycle water Carbon

sou rc e P28ABS
UREA P24ABS
T05A/B
V-Notch H3PO4 P26ABS
V-1.9 m3 NaOH P18ABS
Return
Bio slud ge PAC
sludge P21ABS
Bio slud ge Coagulant
AI
5 X-8701-J13
AI AI AI TI AI D0
OR P OR P pH LI STATIC MIXER f or
O7 filter
MLSS 5
1 F-150m3/h
3

S cum s lu dg e
M M

X-8701-S10A/B X-8701-
P07/08ABS CLAR IFIER B ASIN V02A/B/S
X-8701-S07A/B X-8701-S08A/B X-8701-S09A/B Clarifier s lu dge V-530 m3
P09AS X-8701-P10A/B/ SAND FILTER
ANAER OBIC B ASIN ANOXIC B ASIN A/B AERATIO N BASIN recycle pump Drain water
Pum p room S F-75m3 /h
V-106.6 m3 V-140.1 m3 V-1566 m3 F-m3/h X-8701-S12
pit pump CLARIFIED WATER Sand filt er f eed
F-m3 /h SUMP pum p
P06ABS V-273 m3 F-m3/h
Internal recycle pu mp
F-m3 /h S11
Pum p room pit
Treated water V-1.2 m3

X-8702
LI WW Reu se
5 Package
TI AI LI LI
1
4

X-8701-
Off spec treated
V03A/B/S
water
A/C FILTER
F-75m3 /h

AI X-8701-U01
UV STERIL IZER X-8701-P12A/S S-8703
DISCHERGE PUMP WWT AREA
X-8701-S13 X-8701-S14-1 X-8701-S14-2 F-m3/h (OSBL) DISPOSAL
RETENTION BASIN
FILTERED WATER BASIN CHECK BASIN CHECK B ASIN fo r C SS PON D
V-7000 m3
V-216m3 V-427.3m3 V-328.3m3 (artificial po nd)
V-2 000 000m3
 CORRUGATED PLATE INTERCEPTOR
CPI Tank
- Capacity : 42 ㎥ /hr (0.7 ㎥ /min)
- Water specific gravity : 1.0
- Oil specific gravity : 0.9
- Operating temperature : 10℃
Skimmer
- Type: PIPE
- Quantity: 1 SET
- Size: 6"
Plate Pack
- Type: EIP (Effective oil interceptor plate pack)
- Plate Material: P.P
- Plate Number : 5,400 EA
- Oil Way : 360 EA
- Sludge Way: 360 EA
- Weight (kg) : 540
Plate pack achieves to 50 microns removal
rate at the flow rate of the 42 ㎥ /hr.
 DISSOLVED AIR FLOTATION
PACKAGE
Fluid: CPI EFFLUENT
Flowrate: 42 ㎥ /hr
Surface Skimmer
- Type : SCRAPING
Pipe Skimmer
- Type: FIXED
Bottom Scraper
- Type: SCREW
Fine Bubble Removal Pack
- Type : EIP
 DAF SYSTEM
Recycle Pump(X-8701-P01A/B)
- Quantity: 2 SETS
- Capacity: 18 m3/hr
- Type: CENTRIFUGAL
Air Dissolving Vessel (X-8701-V01A/B)
- Quantity : 2 SETS
- Capacity : 1 m3
- Dimension(mm) : 920(ID) X 1,840H
 BASIC DESIGN
― Flow Rate (Q) : 42 ㎥ /hr
― Free Oil + TSS (S) : 150 ㎎ /ℓ
― Pressure of Saturation Tank (P) : 3.5 atm
― Recycle Water Capacity (R) : 18 ㎥ /hr
― Dissolved Air In Water (Sa) : 13.9 ㎖ /ℓ @38℃
― Dissolve Rate of Air (F) : 0.5
 SAND
FILTER
• TYPE: Vertical , Cylindrical
• FLOW RATE: 72.1 m³/hr
• PRESSURE (DES/OPER): 800 / 400 kPa g
• SS REMOVAL RATE:
-INLET: 100 mg/L
-OUTLET:< 30 mg/L
• FILTRATION MEDIA
-SAND VOLUME:4.23m3
-ANTHRACITE VOLUME:2.82m3
-GRAVAL VOLUME:1.41m3
 ACTIVE CARBON
FILTER
• TYPE: Vertical , Cylindrical
• FLOW RATE: 72.1 m³/hr
• PRESSURE (DES/OPER): 800 / 400
kPa g
• COD REMOVAL RATE:
-INLET: 180~200 mg/L
-OUTLET:< 150 mg/L
• FILTRATION MEDIA
-A.C. VOLUME:8.48m3
-GRAVAL VOLUME:1.41m3
THE QUALITY OF TREATED WATER
1 Temperature: AMB 11 Chrome: 0.5 mg / l
2 pH: 6-9 12 Copper: 2 mg / l
3 BOD: 25 mg / l 13 Zinc: 0.5 mg / l
4 COD: 150 mg / l 14 Cadmium: 0.1 mg / l
5 Suspended substances: 30 mg / l 15 Mercury: 0.01mg / l
6 Total nitrogen: 10 mg / l 16 Lead: 0,5 mg / l
17 Vinyl chloride: 0.05mg / l
7 Total phosphorus : 2 mg / l
18 Organic halogens absorbing: 0,3mg / l
8 Oil products: 10 mg / l
19 Benzene: 0.05 mg / l
9 Phenols: 0,5mg / l
20 Nickel 0.5mg / l
10 Number of Coliform: ˂3000 ea
 DISPOSAL POND OF 2,1 MILLION CUBIC
METERS
Disposal Pond of 2 million cubic
meters - at a distance of 1-2 km from
the UGCC it is planned to build a
reserve Pond for discharge and
accumulation of water for the period
of low water in the Amudarya River.
The reservoir can provide UGCC with
water for 2 - 4 months. A pumping
station is installed at the Pond to
supply water to the UGCC.
• FLUID: Oily sludge
• SOLIDS CONC.(wt%): 15
• TEMPERATURE(oC): AMB
• SUSPENDED S.G: 1.01~1.02
• pH: 5~9

• FLUID: Bio sludge

• SOLIDS CONC.(wt%): 15
• TEMPERATURE(oC): AMB
• SUSPENDED S.G: 1.01~1.02
• pH: 6~9
 CHEMICAL DOSING
Sulfuric Acid (H2SO4 92,5%) for Adjusting pH
SYSTEMS
Caustic Soda (NaOH 20%) for Adjusting pH

Coagulant (PAC 10%) for Coagulation

Coagulant Aid (A-Polymer-Betz Dearborn AP1120P) for Flocculation

Dehydrator (C-Polymer-Betz CP1654) for Dewatering

Urea (CO(NH2)2) for N Sours

Phosphoric Acid (H3PO4 CONTINUUM AEC3192) for P Sours

Glucose (C6H12O6 Glucose syrup) for C Sours

 OPTIMIZATION MEASURES OF
WASTE WATER TREATMENT PACKAGE
Installation Septic tank inway
Sanitary waste water line:
In waste water treatment package is
not considered Sanitary Treatment
Package. Consequence operators are
faced some problems: Increasing
level of sludge in Equalization Basin,
very often blockage strainer. To fix
these problems installed septic tank
the sanitary sewer lines inway
Equalization Basin. On the septic
tank suspended solids are caught via
baffles and strainers, the clarified
water routed to Equalization Basin
by gravity. The accumulated sludge
is removed with vacuum truck.
Covering the Clarifiers from
sunlight:
In the sunlight, algae grows in
the clarifier. As a result, algae
routed with clarified water
flow and create difficulties for
the process: very often
blockages in the strainer of
pumps, blockages in the sand
filter and active carbon filter.
To fix these problems,
covering was installed above
the clarifier to protect it from
sunlight.
Installation Degassing-
separator inway Oily waste
water line:
For increasing level of sludge in
WWT area Retention Basin,
very often blockage CPI Plate
Packs. To fix these problems
installed Degassing-separator
on the Oily waste water line
inway WWT area Retention
Basin. On the Degassing-
separator suspended solids are
caught via baffles, the clarified
oily water routed to WWT area
Retention Basin by gravity. The
accumulated sludge is
removed with vacuum truck.
CONCLUSION
• By providing this presentation, we
hope that you, while studying at the
Ustyurt Gas Chemical Complex, will
deep study the technological
processes and the control system
from the best specialists and enhance
your experience, which will be
necessary for the upcoming
commissioning works of the UZGTL
plant