Unit and student details

Unit code ENG 1010 Unit title PROCESS SYSTEMS ANALYSIS

If this is a group assignment, each student must include their name and ID number and sign the student statement.
Student ID
22817670
Surname
Lee Choong Tong
Given names TienSen John John
Oliver
Student ID 21630283 Surname RAMREKHA Given names KESHAV
Student ID Surname Given names
Student ID Surname Given names

Assignment details
Title of assignment CASE STUDY 2 Authorised group assignment Yes No
Lecturer/tutor Dr.ESTEE YONG SIEK TING Tutorial day and time WED 2-4pm
Due date 07.10.11 Date submitted 07.10.11
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Assessment cover sheet

2


MONASH UNIVERSITY SUNWAY CAMPUS
Department of Chemical Engineering
Semester 2, 2011 ENG 1010 : Process Systems Analysis

Case Study II : Waste Water Treatment Plant






3

Q1) Part 1
Sewage Waste water


To landfill















Pump
Bar Screen
Grit Tank
Primary Settling
Tank
Aeration Tank
Sedimenter
Polymer Tank
4

Q1) Part 2

According to the laws prevailing in Malaysia, there are two effluent standards. Standard A and standard
B. Standard A is generally applicable to activities and industries that are sited within, or in the near
vicinity of, cachement areas. Standard B is generally applicable to both industrial and development
activities throughout the country. Both standard A and B vary and standard A is more stringent. The
allowed temperature of effluent for both standard A and B should not be more than 40
o
C. The pH value
of the discharged liquid for standard A should range between 6.0-9.0 and for standard B, the range is
from 5.5 9.0. The BOD which is the Biochemical Oxygen Demand when measured at a temperature of
20
o
C should have a maximum value of 20mg/L for standard A and 40mg/L for standard B. The allowed
quantity of suspended solid for standard A is 50mg/L and this value is twice for standard B namely
100mg/L. Now for the oil and grease content in the discharged liquid, the difference between standard
A and B is quite large with a 1.0mg/L of allowed oil and grease content in standard A compared to the
10.0mg/L in standard B. For the heavy metals such as zinc tin lead and copper to name a few, the
allowed content for standard A varies from 0 to 2.0 mg/L whereas the allowed content for standard A
varies from 0 to 5mg/L.



Extracted from Environmental Quality (Industrial Effluents) Regulations 2009 (PU (A) 434)
5

2. Reverse Osmosis
Hand Calculation For Reverse Osmosis

W
=Waste water stream

R
= Refined Water steam

P
= Permeate stream

Assuming Steady State, Open System
Accumulation = 0
No Chemical reaction occurring, Generation and Disappearance term is 0 in General mass
balance equation, so the equation generalizes to 0 = In(flow)-Out(flow)
Part 1)
a)Total mass balance equation yields:

w
=
R
+
P
( 3500

x
1
3600
) =
R
+
P
0.97 kg/s =
R
+
P
0.97 -
R
=
P
(1)
Component mass balance equation yields:

W
x
W
=
R
x
R
+
P
x
P
0.97(4 x 10
-5
) =
R
(6 x 10
-7
) +
p
(8.5 x 10
-5
)
3.88 x 10
-5
=
R
(6 x 10
-7
) + (0.97 -
R
) (8.5 x 10
-5
)
4.365 x 10
-5
= 8.44 x 10
-5

R
= 0.517 kg/s
So the mass flow rate of refined water is 0.517 kg/s
% recovery of water
6

=
P
(1- (6 x 10
-7
)) /
W
( 1- (4 x 10
-5
))
=[ 0.517(1-(6 x 10
-7
)) / 0.97(1- (4 x 10
-5
)) ] x 100
= 53.3 %
Therefore 53.3% of water entering the RO unit is recovered as refined water.

Part 2)
System 1

W= 3500kg/h(40ppm)
AR( 0.6 ppm)
Recycled B
System 2

P (125 ppm)
From system 1
Total mass balance equation yields

W =

R
+
p
0.97 =
R
+
P


RO
7

Component mass balance equation yields (Total dissolved solid)

W
x
W
=
R
x
R
+
P
x
P
0.97(4 x 10
-5
) =
R
(6 x 10
-7
) + (0.97 -
R
) (1.25 x 10
-4
)

R
= 0.663 kg/s

p
= 0.307 kg/s

From system 2
Total mass balance yields

A
=
B+

A
=
B
+ 0.663
Component mass balance equation yields

A
x
A
=
B
x
B
+
R
x
R

A
(5 x 10
-5
) =
B
(1.25 x 10
-4
) + 0.663 (6 x 10
-7
)
(
B
+0.663) ( 5 x 10
-5
) = 1.25 x 10
-4

B
+ 3.978 x 10
-7

-7.5 x 10
-5

B
= -3.275 x 10
-5

B
= 0.4367 kg/s

b) So
recycled
=
B
-
P
= 0.4367 0.307
= 0.1297 kg/s

Percentage recycles required:

recycled
/
B
= (0.1297/0.4367) x 100
= 29.7 %

8

3. Mass Balance for Flocculation- filtration

Basis: 100 kg/hr
Breaking down system into sub-systems for calculations:
Performing mass balance on Flocculation tank








Overall Mass Balance:

3
+
4
=
7
+
6

3
+ 100 =
7
+
6
----------- (1)

Flocculation
Tank

4
Water: 65kg/hr
Colloids: 35kg/hr

6
Water: 0.01
Colloids: 0.55
Alum: 0.35

7
Water: 0.94
Colloids: 0.05
Alum: 0.01

3
Water: 1 x y
Colloids: y
Alum: x
9

Component Mass Balance on Alum:
x
3
= 0.01
7
+0.35
6
----------- (2)
Component Mass Balance on Colloids:
y
3
+ 35 = 0.05
7
+0.55
6
----------- (3)

Performing mass balance on Mixer






Overall Mass Balance:

1
+
2
=
3
For Alum:

1
+ 0.01
2
= x
3
---------- (4)

1
=
3
0.25
7
------------(5)

2
= 0.25
7

0.05(0.25
7
) = y
3
0.0125
7
= y
3
------------(6)
From (4)

1
+ 0.01(0.25
7
) = x
3

Using (5),

1
+ 0.0025
7
= x
3

3
0.25
7
+ 0.0025
7
= x
3

Mixer

3
Water: 1 x y
Colloids: y
Alum: x

1
Alum: 1

2
Water: 0.94
Colloids: 0.05
Alum: 0.01
10

3
0.2475
7
= x
3
Using (1),

7
+
6
100 0.2475
7
= x
3

Using (2),
0.7525
7
+
6
100 = 0.01
7
+ 0.35
6

0.65
6
+ 0.7425
7
= 100 ---------- (a)

From (3),
y
3
+ 35 = 0.05
7
+ 0.55
6
0.0125
7
+ 35 = 0.05
7
+ 0.55
6

0.55
6
+ 0.0375
7
= 35 ----------- (b)

Solving (a) and (b) by simultaneous equations,

6
= 57.91 kg/hr

7
= 83.98 kg/hr
Subs (1)

3
=
7
+
6
100

3
= 41.89 kg/hr
Therefore
1
= 41.89 0.25(83.98) = 20.895 kg/hr
Answers:
Amount of pure alum required to treat 100 kg/h of wastewater = 20.895 kg/hr
Mass flowrate of treated wastewater (filtrate) = 57.91 kg/hr
Mass flowrate of filter cake = 83.98 kg/hr

11

4. Water Pumping
Part (a)
V = 80m
3

T = 20
o
C
v = 4m/s

V = 8

0 x
1
3600
= 0.0222 m
3
/s

To find area of cross section of pipe,
V = vA
A =

=
0.0222
4
= 5.56 x 10
3

Area of cross section =

2

Calculating D = 84.138 mm

Therefore pipe with largest diameter that will achieve a velocity of at least 4 m/s at the required
water flow rate = 90mm
12

Part (b)


Viscosity = 0.001Pas
Density = 1000kg/m
3

Length of straight pipe = 120m
3 open gate valves, 5 90
o
elbows
Open to atmosphere


p
1
= p
2
,
therefore,

Assume velocity in heat exchanger is effectively zero. Then v
1
= v
2
= 0
(z
2
z
1
) = 4.5 3 = 1.5m
Friction loss in pipes,
Total length of pipes = 120 m
Velocity of liquid in 90 mm diameter pipes =
80
3600 (

2
4
)
= 3.493 m/s
Reynolds number =
3.395 1000 0.090
1.0 103
= 305550 (hence turbulent)
13

Friction factor for smooth pipes = 0.079 Re
-0.25
= 4.628 x 10
-3
= 15.349 m Hence friction head loss in straight pipes

Friction Loss in fittings/equipment,
5 x 90 degree bends: (5 @ 0.75) = 3.75 velocity heads
3 open gate valve: (3 @ 0.25) = 0.75 velocity heads
1 smooth entrance to pipe from tank: 0.5 velocity heads
Entrance to heat exchanger from pipe: Take this as a sudden enlargement with A2 much greater than
A1, so KL = 1.0 velocity heads.
Total loss in fittings/equipment = 6 velocity heads based on pipe diameter
= 6 x

2
2
= 3.73 m

Total pump head required per kg fluid = -

= 1.5 + 15.349 + 3.73 = 20.579 m

Thus we need to select a pump which will develop a differential head of at least 20.579m at a flow rate
of 80m
3
/h of water.
14



Pump B will deliver a head of 20.5m at 80m
3
/h.
Pump C will deliver a head of 25.5m at 80m
3
/h.

Pump C is therefore most suitable for this application as the minimum differential head required is
20.579m and Pump B does not reach that value.

15

Part (c)
Power requirement
Pump power requirement per kg fluid = -

Where w
s
is the work done per kg of the fluid
Therefore, -w
s
= 25.5 x 9.81 = 250.155 J/kg

Pump delivered power =250.155 x
80 1000
3600
= 5559 W

Pumps overall efficiency = 60 %
Therefore, input power required = 1.6 x 5559 = 8894.4 W

16

Self-Assessment
LEE CHOONG TONG TIEN SEN JOHN JOHN OLIVER Question 1, cross checked hand calculation,
editorial team.

RAMREKHA KESHAV Question 4, verified calculations and report format