CALCIUM REMOVAL SYSTEM (DE- CALCIUM SYSTEM)

PRESENTED BY: ANGELO MAAMBONG AMISTAD

DESIGN BASIS
Supernatant Capacity = 200 m3/ hr Purpose: Treatment of Supernatant wastewater for discharge and reuse application.
A. Inlet Waste Water Quality
ITEM UNIT VALUE

pH
TSS Turbidity COD T- Alkalinity TOC

ppm NTU ppm ppm ppm

6.5 ~ 8.5
10 5.0 20 50 7.0

De- Calcium System

B. Treated Water Quality

ITEM UNIT VALUE

Si
Na

ppm
ppm

10
>200

pH Ca

ppm

6.5 ~ 8.2 < 30

Ca
Mg Fe Mn Cl SO4 NO3 Al Ni Zn

ppm
ppm ppm ppm ppm ppm ppm ppm ppm ppm

700
100 0.05 1.0 20 2200 1.5 0.2 0.01 <0.01

Other Inlet Water Specification: 25OC and 0.1 MPa

PROCESS OVERVIEW
PolyFerric Sulfate NaOH CaCO3 (Recycled) Na2CO3 NaOH Polymer NaOH H2SO4

Supernatant

De- Ca De- Ca Reaction Tank Reaction Tank pH Adjust Tank De- Ca Thickener No. 2 No. 1 (224TK04) (224TH01) (224TK02) (224TK03)

De- Ca Water Pond (224PD02)

De- Ca Water

CaCO3 (Sludge)

DE- CA MAIN PROCESS AREA

pH Adjust Tank

No. 2 Reaction Tank

No. 1 Reaction Tank

224TK04

224TK03

224TK02

224PD02
De- Ca Water Pond

224TH01
De- Ca Thickener

MAIN PROCESS DESCRIPTION

* REACTION TANK NO.1 (224TK02) * Supernatant Water enters this tank Soda Ash (Na2CO3) and Caustic Soda (NaOH) are dosed into this tank 10% NaOH is used to raise the pH between 10 ~ 11 (AIC-101) 10% Na2CO3 (dosing rate at 4.25 m3/ hr) is used as softener to replace Ca2+ present in the wastewater Overflow goes into Reaction Tank No. 2 (224TK03) Main Chemical Reaction: CaSO4 + Na2CO3 (slurry) Na2SO4 + CaCO3(s)

( Supernatant Water)

Note: A large fraction of CaCO3 Sludge is recycled back to Reaction Tank No. 1 (224TK02).

MAIN PROCESS DESCRIPTION

* REACTION TANK NO. 2 (224TK03) * Other than the overflow from Reaction Tank No. 1 (224TK02), 10% NaOH, 10% Na2CO3 (valve is normally closed) and PolyFerric Sulfate (PFS or Fe2(SO4)3) are dosed into this tank.

10% NaOH is for pH control between 10 ~ 11 (AIC-102) before overflow goes into De- Ca Thickener (224TH01)

PFS (conc. = 335 mg/L & dosing rate at 1.2L/ min) is used as coagulant
Overflow goes into the De- Ca Thickener (224TH01)

MAIN PROCESS DESCRIPTION

* DE- CA THICKENER (224TH01)* Sedimentation and Bridging

Polymer PA331 (3 mg/ L, dosing rate at 8 L/ min) is used in this unit

Settling sludge, CaCO3 slurry, is pumped out for reuse or for recirculation back to Reaction Tank No. 1 (224TK02)

Treated water overflows to pH Adjust Tank (224TK04)

MAIN PROCESS DESCRIPTION

*pH ADJUST TANK (224TK04)* pH (AIC-103) of treated water is adjusted to 6.5 ~ 8.2 where NaOH and H2SO4 solution are used as adjusting reagents

H2SO4 is dosed when pH > 8.2 and it is stopped when pH < 7.7 NaOH is dosed when pH < 6.5 and it is stopped when pH > 7.0
Treated water overflows to the De- Ca Water Pond (224PD02)

MAIN PROCESS DESCRIPTION

* DE- CA WATER POND (224PD02)*

Served as reservoir of De- Ca Water Supply Softened water

Target Ca conc. 30 ppm

DE- CA CHEMICALS
A) Sulfuric Acid (H2SO4)
B) Polyferric Sulfate or PFS (Fe2(SO4)3) C) Caustic Soda (NaOH) D) Soda Ash (Na2CO3)

E) Polymer (PA-331)

CHEMICALS PREPARATION & FEEDING

CHEMICAL CONSUMPTION
= 1,048 kg/ day = 5 m3 = 3 m3/ hr x 15 m = 4,400 kg/ day = 5 m3 = 3 m3/ hr x 15 m = 1,704 kg/ day = 2 m3 = 0.8 L/ min x 20 m = 600 g/ hr = 600 L/ hr, 14400 L/ day = 5 m3 x 2 sets = 8 L/ min x 20 m = 107 ton/ day = 30 m3 x 2 sets = 4.2 m3/ hr x 15 m

10% H2SO4 98% H2SO4 Dil. H2SO4 Storage Tank Dil. H2SO4 Feed Pump 10% NaOH 24% NaOH Dil. NaOH Buffer Tank Dil. NaOH Feed Pump Polyferric Sulfate (PFS) 11% as Fe PFS Storage Tank PFS Feed Pump Polymer 3 ppm x 200 m3/ hr 600/ 0.1% Polymer Tank Polymer Dosing Pump Na2CO3 10% Na2CO3 Slurry Tank Slurry Feed Pump

CHEMICALS PREPARATION & FEEDING

CHEMICALS PREPARATION A) 10% NaOH

Dilution Tank (224TK08) It has a capacity of 1.0 m3 concentration takes place. Dilution Procedure:

where dilution of 24% NaOH to 10%

1) Fill the tank with the required amount of raw water by opening valve 224DIV043. Auto filling starts at LL level (7%) and stops at M2 level (68%). 2) Fill with required amount of 24% NaOH into the tank by opening valve 224DIV039. Auto filling starts at M2 level (68%) and stops at H level (86%). 3) Agitator (224AG08) auto start to stir and stop after certain time. Diluted NaOH Buffer Tank (224TK09) The tank has a capacity of 5.0 m3 to handle 10% NaOH solution supplied from NaOH Dilution Tank.

CHEMICALS PREPARATION & FEEDING

B) 10% H2SO4 Dilution Tank (224TK10) It has a capacity of 2.0 m3 where dilution of 98% H2SO4 to 10% concentration takes place. Dilution Procedure: 1) Fill the tank with the required amount of raw water by opening valve 224DIV084. Auto filling starts at LL level (23%) and stops at M2 level (88%). 2) Fill required amount of 98% H2SO4 into the tank by opening valve 224DIV081. Auto filling starts at M2 level (88%) and stops at H level (94%).

3) Agitator (224AG10) auto start to stir and stop after certain time.
Diluted H2SO4 Storage Tank (224TK11) It has a capacity of 5.0 m3 to contain the 10% H2SO4 solution supplied from Dilution Tank.

CHEMICALS PREPARATION & FEEDING

C) 10% Na2CO3

Mixing Tank (224TK05) This tank has a capacity of 30 m3 where dissolution of powdered Na2CO3 to 10% concentration takes place. Dissolution Procedure:
1) Fill the tank with the required amount of raw water by opening VALVE V-196. Auto filling starts at L level (7%) and stops at H level (91%). 2) Run Agitator (224AG05) to stir when level reaches 50%. 3) Fill required amount of Na2CO3 when agitator is running already. Slurry Tank (224TK06/ 224TK07) Each tank has a capacity of 30 m3 and serve as storage tank for the 10% Na2CO3 slurry prior for feeding to Reaction Tank No. 1 (224TK02).

CHEMICALS PREPARATION & FEEDING

D) PolyFerric Sulfate (PFS) PFS Bin It has a capacity of 1.0 m3 and already prepared in aqueous solution form. PFS Storage Tank (224TK14) This tank has a capacity of 2.0 m3 designed to contain 11% (as Fe) Polyferric Sulfate solution coming from the 1.0 m3 bin. E) Polymer No.1/ No. 2 Polymer Tank (224TK12/ 224TK13) These tanks have a total capacity of 5.0 m3 and use to contain PA-331 Polymer solution of 0.1% concentration. Dissolution Procedure: 1) Fill required amount of raw water into the tank by opening valve 224DIV088 (or 224DIV101). 2) Put required amount of PA-331 powder into the Kurifeeder. 3) Agitator (224AG12/ 224AG13) auto starts at M level (18%).

DE- CA DCS SCREEN

The De- Ca operation has no DCS control or intervention.

DE- CA LCP SCREEN

De- Ca operation is controlled via LCP.

DE- CA LCP SCREEN

DE- CA LCP SCREEN

LOCAL CONTROL PANELS

Polymer Local Panel (LCP-1)

Door 1

Door 2

Door 3

Door 4

De- Ca System Control Panel

Na2CO3 Mixing Local Panel (LCP-2)

MAIN PROCESS CONTROL SWITCH

AGITATORS & REDUCTION GEARS

MAIN PROCESS CONTROL SWITCH

CONTROL VALVES & PUMPS

DE- CA CHEMICALS CONTROL SWITCH

NaOH DILUTION CONTROL VALVES, AGITATOR & PUMPS

DE- CA CHEMICALS CONTROL SWITCH

H2SO4 DILUTION CONTROL VALVES, AGITATOR & PUMPS

DE- CA CHEMICALS CONTROL SWITCH

POLYFERRIC SULFATE OPERATION CONTROL VALVES & PUMPS

DE- CA CHEMICALS CONTROL SWITCH

SODA ASH OPERATION CONTROL VALVES, AGITATOR & PUMPS

DE- CA CHEMICALS CONTROL SWITCH

POLYMER OPERATION CONTROL VALVES, AGITATORS & PUMPS

GENERAL STEP-BY- STEP PROCEDURE IN LCP OPERATION

LCP Display Monitor Circuit Breakers

Field Sensor Circuit Breakers

1) Switch ON Main Incoming Power.

2) Switch ON circuit breakers for LCP Display Monitor and other breakers for field instruments/ sensors.

3) Switch ON circuit breakers of the specific equipment or valve for operation.

GENERAL STEP-BY- STEP PROCEDURE IN LCP OPERATION

4) Turn the selector switch to the desired mode of operation. For dilution operation, turn the selector switch to ON mode.

NORMAL OPERATION MODE

OPERATION
A) De- Ca Main Process B) Na2CO3 Operation C) NaOH Operation D) H2SO4 Operation E) PFS Operation

AGITATORS RUN RUN AUTO AUTO AUTO

PUMPS AUTO RUN (Transfer) AUTO (Feed) AUTO AUTO RUN (Loading) AUTO (Feed) AUTO

CONTROL VALVES AUTO AUTO AUTO AUTO AUTO AUTO

REDUCTION GEARS RUN -

G) Polymer Operation (w/ START button)

5) Make the necessary adjustments on the settings of flow or dosing rate and proceed to other De- Ca operation.

OPERATING PROCEDURE

AGITATORS

Selection switch to AUTO mode - NaOH Dilution Tank Agitator (224AG08) - H2SO4 Dilution Tank Agitator (224AG10) - No. 1 Polymer Tank Agitator (224AG12) - No. 2 Polymer Tank Agitator (224AG13) Selection switch to RUN mode at start up - No. 1 Reaction Tank Agitator (224AG02) - No. 2 Reaction Tank Agitator (224AG03) - Reduction Gear for Rake (224RG01) - Reduction Gear for Coagulator A/B/C (224RG02A/B/C) - pH Adjust Tank Agitator (224AG04) - Na2CO3 Mixing Tank Agitator (224AG05)

Thickener (224TH01)

OPERATING PROCEDURE

PUMPS
Selection switch to AUTO mode De- Ca Water Pump A/B (224PU04A/B) CaCO3 Slurry Pump A/B (224PU06A/B) Diluted NaOH Transfer Pump A/B (224PU09A/B) Diluted NaOH Feed Pump A/B (224PU10A/B) Diluted H2SO4 Transfer Pump A/B (224PU11A/B) Diluted H2SO4 Feed Pump A/B (224PU12A/B) Na2CO3 Slurry Feed Pump A/B (224PU08A/B) Polymer Feed Pump A/B (224PU13A/B) Polyferric Sulfate (PFS) Feed Pump A/B (224PU14A/B) De- Ca Area Sump Pump (224PU15) Selection switch to RUN mode PolyFerric Sulfate (PFS) Loading Pump (224PU16)

OPERATING PROCEDURE

TANKS AUTOMATIC VALVES Switch auto valves to AUTO mode

NaOH Dilution Tank Inlet Valve (XV-107) No. 1 Reaction Tank Dosing Valves (XV-101 and XV-102) No. 2 Reaction Tank Dosing Valves (XV-103 and XV-104) pH Adjust Tank Dosing Valve (XV-106) H2SO4 Dilution Tank Inlet Valve (XV-109) pH Adjust Tank Dosing Valve (XV-105) Raw Water Inlet Valve to NaOH Dilution Tank (XV-108) Inlet Valve to H2SO4 Dilution Tank (XV-110)

OPERATING PROCEDURE

pH METERS & OTHER INSTRUMENTS

pH - Reaction Tank No. 1 (AIC-101= 10 ~ 11) - Reaction Tank No.2 (AIC-102= 10 ~ 11) - pH Adjust Tank (AIC-103= 6.5 ~ 8.2)

Density - Na2CO3 Mixing Tank (AIA-104= 1, 100 kg/ m3)

Flow - FIQ-101 - FIQ-102 - FI-103 - FI-104
Note: Monitor all level gauges/ sensors, pressure gauges and instrument air supply.

OPERATING PROCEDURE
DESIGN STREAMS FLOW RATE FOR PUMPS A) De- Ca Water Pump (224PU04A/B) B) CaCO3 Slurry Pump (224PU06A/B) C) Dil. NaOH Transfer Pump (224PU09A/B) D) Dil. NaOH Feed Pump (224PU10A/B) E) Dil. H2SO4 Transfer Pump (224PU11A/B) F) Dil. H2SO4 Feed Pump (224PU12A/B) G) Na2CO3 Slurry Feed Pump (224PU08A/B) H) Polymer Feed Pump (224PU13A/B) I) Polyferric Sulfate (PFS) Feed Pump (224PU14A/B) J) De- Ca Area Sump Pump (224PU15) 200 m3/ hr 45 m3/ hr 3 m3/ hr 3 m3/hr 3 m3/ hr 3 m3/ hr 6 m3/ hr 8 L/ min 1.2 L/ min 18 m3/ hr

SUMMARY ON CHEMICAL REQUIREMENTS PER DISSOLUTION/ DILUTION

Chemicals Optimum Tanks Capacity (m3) Required Weight/ Volume Start- Up Operation Normal Operation

10% NaOH
Raw Water 24% NaOH 10% H2SO4 Raw Water 98% H2SO4 10% Na2CO3 Raw Water 100% Na2CO3 0.1% Polymer Raw Water Polymer (PA-331)
Polyferric Sulfate (PFS)

1.02
647 L 373 L 2.10 1,976 L 124 L 29.90 29.02 m3 3,289 kg (3.3 tons) 4.40 (per tank) 4,400 L 4.49 kg 2.00 -same3,800 L 3.88 kg 1.6 m3 26.4 m3 2,992 kg (3.0 tons) 1,411 L 89 L 546 L 314 L

ALARMS & COUNTERMEASURES

GENERAL NATURE OF ALARM EQUIPMENT/ UNIT INVOLVED 1) Tank Agitator 2) Reduction Gear 1) TRIP Overload 3) Pump Stops operating CAUSE AUTOMATIC RESPONSE Not Correctly Operate COUNTERMEASURES Reset Breaker Reset Breaker Check setting current against rating current of motor and adjust main circuit breaker. Check motor and mechanical rotation of driving equipment. 1) De- Ca Water Pond 2) HIGH LEVEL 2) De- Ca Area Sump 3) Chemical Tanks
3) INSTRUMENT AIR PRESSURE LOW

Stops operating

The incoming flow rate exceed design capacity or; Flow rate of pump (transfer or feed) is below the design capacity. No air supplied.

Pump start

Check and control incoming flow rate. Adjust the flow rate.

the

Stop Loading pump (for PFS case only)

Valves stop functioning. Check for air leakage/ supply.

De- Ca Pneumatic Operated valves.

1) Rxn Tank No. 1

2) Rxn Tank No. 2 4) HIGH pH 3)pH Adjust Tank

Excess dosage of NaOH or Na2CO3.

Excess NaOH. dosage of

Adjust the chemical dosage thru the needle valve at the dosage point.

Insufficient dosage of H2SO4 soln. or excess dosage of NaOH.

GENERAL NATURE OF ALARM

ALARMS & COUNTERMEASURES

EQUIPMENT/ UNIT INVOLVED CAUSE AUTOMATIC RESPONSE

COUNTERMEASURES

1) Rxn. Tank No. 1 2) Rxn. Tank No. 2 3) pH Adjust Tank

Insufficient dosage of NaOH or Na2CO3. Insufficient dosage of NaOH solution. Insufficient dosage of NaOH or excess dosage of H2SO4. Insufficient dosage of raw water or excess dosage of Na2CO3. Insufficient dosage of Na2CO3 or excess dosage of raw water. Overload Too thick or too much of sludge. Emergency Stop button was pushed. Wire not connected. properly

Adjust the chemical dosage thru the needle valve at the dosage point.

5) LOW pH

A) Reduce the charging or loading of Na2CO3. B) Increase the raw water flow rate by opening XV-111. A) Increase the charging or loading of Na2CO3. B) Decrease the raw water flow rate by closing XV-111. Stop Operation Equipment stops operating. Reset breaker Discharge the sludge. Reset the button. Reconnect the wire and reset ELCB. Fill up the tank.

6) HIGH DENSITY

Na2CO3 Mixing Tank

7) LOW DENSITY

Na2CO3 Mixing Tank

8) OVER TORQUE 9) TORQUE HIGH

10) EMERGENCY STOP 11) EARTH LEAKAGE

Reduction Gear for Rake LCP Emergency Stop Button LCP Pumps in De- Ca Area

12) PUMP DRY

Shortage of water or content.

ENVIRONMENTAL BENEFITS
Wastewater/ Supernatant Circulation & Discharge
Reference Timeframe Jan- Dec 2007 Jan- Sep 2008 Jan- Dec 2008 Jan- Dec 2009
(w/ CBNH-2) Tot. Discharge from Tailings Dam (m3) Recycle to Plant (m3) Discharge to Pier (m3) % Discharge to Pier TSS DISCHARGE LOAD (kg)

1,323,989.3 1,148,366.7 1,500,000.0 (Estimated) 3,000,000.0 (Estimated)

411,589.7 472,093.2 600,000.0 (Estimated) 2,784,000.0

906,333.4 673,162.0 900,000.0 (Estimated) 216,000.0

68.45 58.62 60.00 7.2

9, 063.3 6, 731.6 9, 000.0 2, 160.0

ADDITIONAL DATA: NO. OF OPERATING DAYS IN A YEAR = 315 DAYS AVERAGE TSS DISCHARGE TO PIER = 10 ppm

DISCHARGE PERMIT FEE (CY 2008) = Php 55, 000. 00

DISCHARGE PERMIT FEE (CY 2009) = Php 20, 800. 00

% REDUCTION IN DISCHARGE TO PIER = 52.8 % % REDUCTION IN TSS DISCHARGE LOAD = 76.0 %