New Compiled Wastewater Report2

TABLE OF CONTENTS
I. WASTEWATER TREATMENT
Primary Treatment of Wastewater 3
Design of Neutralization Contact Basin 11
Design of a Clarifier 15
Design of Upflow Anaerobic Sludge Blanket Reactor 1 27
Design of Upflow Anaerobic Sludge Blanket Reactor 2 37
Design of Trickling Filter 51
Design of Aerated Lagoon 60
II. PIPING SYSTEM
Introduction 70
Codes and Standards 73
Components of a Piping System 74
Factors to be Considered 92
Principles in Piping Design 94
Sample Piping Design 109
III. Instrumentation and Control
Introduction 118
Definitions 119
Types of Controllers 120
Types of Sensors 122
Types of Actuators 126
Sample Design 127
DESIGN OF WASTEWATER TREATMENT FACILITIES, PIPING SYSTEM, AND INSTRUMENTATION

C.P. Dionisio | M.D. Mendoza | K.J.O. Raymundo | M.Y. Saligue | L.A. Yumul 1
OBJECTIVES
General
To design a wastewater Treatment Facility with Piping System and
Instrumentation and Control
Specific
• To design a Neutralization Contact Basin

• To design a Trickling Filter
• To design an Aerated Lagoon
• To design a Clarifier
• To design an Anaerobic Sludge Reactor
• To design a Piping System
• To design an Instrumentation and Control System

PRIMARY TREATMENT OF WASTEWATER
INTRODUCTION
Primary treatment involves basic processes to remove suspended solid and

reduce the biochemical oxygen demand (BOD). There is also a so-called advanced
primary treatment which is described as the enhanced removal of suspended solids
and organic matter from the wastewater. This is typically accomplished by chemical
addition or filtration.
NEUTRALIZATION
This step is conducted before the main step of wastewater treatment, that is
clarification, to fulfill the overall wastewater treatment objectives.
Neutralization is a common practice in wastewater treatment and waste

stabilization. If a waste stream is found to be hazardous because of corrosivity,
neutralization is the primary treatment used. Moreover, neutralization is used as a
pretreatment system before a variety of biological, chemical, and physical treatment
processes. Since many chemical treatment processes, such as metal precipitation,
coagulation, phosphorus precipitation, and water softening are pH dependent, the pH
of these processes is adjusted to achieve maximum process efficiency. Furthermore,
the pH of the effluent wastewater from different industrial activities also requires
adjustment prior to its discharge into receiving water bodies.
Neutralization is the process of adjusting the pH of water through the addition

of an acid or a base, depending on the target pH and process requirements. Some
processes such as boiler operations and drinking water standards need neutral water
at a pH of 7. Water or wastewater is generally considered adequately neutralized if (1)
its damage to metals, concrete, or other materials is minimal; (2) it has little effect on
fish and aquatic life; (3) it has no effect on biological matter (i.e., biological treatment
systems).

FACTORS TO BE CONSIDERED IN DESIGNING A NEUTRALIZATION TANK
The design of a neutralization tank is concerned with the following

considerations:
1. Influent wastewater properties

2. Detention time
3. Desired effluent wastewater properties
STEP-BY-STEP PROCEDURE IN DESIGNING A NEUTRALIZATION TANK
The step-by-step procedure in designing a neutralization tank is as follows:
1. Given the influent data, solve for the acid dosing

2. Calculate the basin volume using the volume of water and the volume of the
acid to be added.
3. Compute for the surface area.
4. Calculate the dimensions of the basin.
5. Solve for the channel width.
6. Compute the baffle length.
7. Calculate the total volume of effluent.
WASTEWATER TREATMENT PROCESS

INTRODUCTION
In various chemical industries, the manufacturing of useful products also

generates undesirable products which include wastewater. These by-products are
necessary to be treated by undergoing physical, chemical, and sometimes biological
processes before discharging it to the environment. Wastewater treatment has been a
huge factor of designing a manufacturing plant because of its large volume, harmful
contaminants present, and odor. Physical and chemical characteristics of the treated

wastewater are regulated by the government to assess if it is safe for the receiving
body of water.
For Esolite Chemicals Inc., the huge amount of wastewater is generated by the
washing processes in the Nutsche Filters. The manufacturing plant produces 8998.08
kg of wastewater per batch. This wastewater is treated in order to meet the required
effluent characteristic for the discharge in the nearest body of water in Brgy. Bancal,
Carmona, Cavite.
The wastewater treatment process of Esolite Chemicals Inc. includes collection

of wastewater (flow equalization basin), decreasing the pH or neutralization
(neutralization contact basin), removal of settleable solids and scums (clarifier), and
removal of organic matters from high COD and BOD content (upflow anaerobic sludge
blanket reactor, trickling filter, & aerated lagoon).
STATEMENT OF THE PROBLEM
The production of tylose powder from abaca stripping wastes involves chemical
processes which lead to generation of large amount of wastewater. An approximate
amount of 17,996.16 kg of wastewater per day is being generated by the
manufacturing plant due to the washing in the nutsche filters. Its disposal is a major
problem because of its odor, large amount, and harmful contaminants that might
affect the whole plant and the environment.
The properties of the wastewater generated by Esolite Chemicals Inc. were

tested by Mach Union Water Laboratory, Inc. and the results are the following:
Table 9.1 Properties of Influent Wastewater

WASTE WATER CHARACTERISTICS
Parameter Value
BOD5 1699 mg/L
COD 88352 mg/L
TSS 931 mg/L
pH 10.6

The results prove that the wastewater generated by the plant is harmful due to
the chemical processes involved in the manufacturing. As a legally responsible
industrial plant, it is the duty of the company to treat the wastewater as to comply with
the standard effluent characteristics set by the Department of Environmental and
Natural Resources.
To solve this problem, the manufacturing plant will employ a wastewater

treatment facility that may handle the generated waste. The equipment includes a flow
equalization basin, neutralization contact basin, clarifier, upflow anaerobic sludge
blanket, trickling filter, and aerated lagoon.

OBJECTIVES
General Objective:
The main objective is to treat the wastewater generated from the production of
tylose powder from abaca stripping wastes with the following influent characteristics
shown in Table 9.1
Specific Objectives:
• To determine the processes suitable for the treatment of wastewater generated

from the washing in all filtration process
• To design the necessary equipment properly and efficiently for the treatment of
wastewater
• To identify the safest and allowable wastewater characteristics suitable for the
discharge in the nearest body of water located at Brgy. Bancal, Carmona, Cavite
• To determine the final effluent characteristics which would comply with the
legal requirements and standards of DENR such as:
Table 9.2 Standard Effluent Properties

CLASS C EFFLUENT STANDARDS
Parameter Value
BOD5 50.0 mg/L
COD 100.0 mg/L
TSS 100.0 mg/L
pH 6.0 – 9.0
* Water Quality Guidelines and General Effluent Standards of 2016, DENR
Administrative Order No. 2016-08, Table 9, p. 20

DETAILED WASTEWATER TREATMENT PROCESS
The wastewater facility is focused on reducing the pH, biological oxygen

demand, chemical oxygen demand, and total suspended solids of the wastewater
generated during the production of tylose powder. This is done by collecting the
wastewater, reducing the pH, and removing the organic matters from the treated
effluent.
The wastewater treatment process of the company is mainly consists of the

following process: (1) collection of wastewater; (2) reducing the pH; (3) removing of
settleable soilds and scums; (4) reducing chemical oxygen demand via anaerobic
treatment; (5) reducing of biological oxygen demand and filtering of sludge; (6) final
treatment to reduce COD, BOD, and TSS via aerobic reaction.
1. Collection of Wastewater
The main source of wastewater is the filtrates produced in the nutsche filters.
For every batch, the wastewater produced is 8998.08 kg. The production has two
batches per day, thereby doubling the amount of wastewater. The wastewater
generated will be collected for 6 days before treatment in a flow equalization basin.
Thus, the total amount of influent to be treated is 107,976.96 kg.
2. Neutralization
The influent incoming has a pH of 10.6. Neutralization contact basin is used to

neutralize the wastewater to pH of 7.0. It is made of reinforced concrete and has four
channels for better contact and treatment. Hydrochloric acid is added to adjust the ph.
The total residence time is 23.50 hours. After adjusting the pH the effluent is now
111,109.20 kg.
3. Clarifying
A rectangular concrete clarifier is used to settle the solids from the 111,109.20
kg neutralized wastewater coming from the neutralization contact basin. The influent
contains 931 mg/L of TSS and 1699 mg/L of BOD. The clarifier has an efficiency of

70% total suspended solids removal and 30% BOD removal. The settling time for the
influent is 4 hours. The settleable solids from the influent are removed by the flights.
The flights (scrapers) scrape the bottom of the tank and present consistent sludge
flows to the hoppers. When the flights travel to the surface of the rectangular tank
along the collector chain, the scum/foam is pulled by the flights to the scum trough.
The total solids removed from the neutralized wastewater are 132.3247 kg. The
resulting effluent will now have a total amount of 110,983.4541 kg with 103.6588 kg
BOD and 24.3436 kg TSS.
4. Anaerobic Process Treatment
The effluent coming from the clarifier is pumped (5 hp) to the upflow anaerobic
sludge blanket reactor 1. The COD content of the incoming influent is 7692.0016 kg.
Two UASB reactors are used to treat the wastewater using acetic acid-forming bacteria
(acetogens) and methane-forming archaea (methanogens). These microorganisms are
loaded after the UASB reactor is completely filled up. UASB reactors remove 95% of
the COD. Methane is produced due to the anaerobic process treatment. The total
methane produced by the two UASB reactors per month is 18.63 kg. Each reactor has
a residence time of 4 hours. The amount of effluent from the UASB reactor 2 is
103,328.27 kg. The amount of COD still present in the effluent is 17.96 kg.
5. Biological Degradation using Filter Media
The 103,328.27 kg of wastewater is treated in a trickling filter for 5.5 hours. A

trickling filter is used to reduce the BOD content of wastewater from 1189.3 mg/L to
118.93 mg/L through the biological degradation of organic material by bacteria and
micro-organisms (pseudomonas) contained on the filter media. The total effluent of
103,241.51 kg will proceed to the aerated lagoon.
6. Aerobic Process Treatment
The effluent from the trickling filter is transferred to the aerated lagoon. The
aerated lagoon is used to reduce the organic matter content of wastewater through
aerated activity of microorganisms which convert it to cell tissues or gases. The TSS,

BOD, and COD content is reduced in this process. The total time for the process is
30.96 hours. The solids removed from the lagoon are 40.59 kg while the final effluent
is 103,200.92 kg.
7. Discharge of Effluent
The discharged effluent amounting to 103,200.92 kg now has 7.0 pH, 17.84
mg/L of BOD, 55.86 mg/L of TSS, and 44.18 mg/L of COD. These properties conform
to the effluent standard of Class C type body of water based from DENR-DAO No. 2016-
08. The final effluent with 4.3m3/h flowrate is discharged to Pasong Pari River. The
total sludge collected from clarifier, UASB reactors 1 and 2, trickling filter, and aerobic
lagoon has a total amount of 7908.28 kg. This will be collected and disposed via third
party treater.
Shown in Table 9.3 is the removal efficiencies for BOD, COD, and TSS of
neutralization contact basin, clarifier, upflow anaerobic sludge blanket reactor,
trickling filter, and aerated lagoon. The equivalent levels of BOD, TSS, and COD of the
influent and effluent is also shown.
Table 9.3 Summary of Efficiency of Wastewater Treatment Equipment

Proposed Wastewater Treatment Equipment
Reduction Influent Effluent
Equipment
Efficiency
Neutralization Contact
- 10.6 7.0
Basin
70% (TSS) 931 279.3
Clarifiera
30% (BOD) 1699 1189.3
1 95% (COD) 88352 4417.6
UASBb
2 95% (COD) 4417.6 220.88
Trickling Filterc 90% (BOD) 1189.3 118.93
85% (BOD) 118.93 17.84
Aerated Lagoonb 80% (TSS) 279.3 55.86
80% (COD) 220.88 44.18
(a) Handbook of Water and Wastewater Treatment Plant Operations, Frank R.
Spellman, page 565; (b) Metcalf & Eddy, 4th ed, page 1007, 818; (c) Environmental
Engineer’s Handbook. 2nd Edition. Section 7.23

Table 9.4 Summary of Properties of Wastewater and Treated Wastewater
Water Quality
Parameter Standard* Influent Effluent
BOD, mg/L 50.0 1699 17.84
COD, mg/L 100.0 88352 44.18
TSS, mg/L 100.0 931 55.86
pH 6.0 – 9.0 10.6 7.0
* Class C, Water Quality Guidelines and General Effluent Standards of 2016, DENR
Administrative Order No. 2016-08, Table 9, p. 20
NEUTRALIZATION CONTACT BASIN

DESIGN PROBLEM
A total of 8998.08 kg per batch of wastewater is discharged from nutsche filter

1, 2, and 3 after each filtration process of Esolite Chemicals Inc. that completes 2
batches of operation per day. The wastewater will be collected for 6 days before being
treated. Design a neutralization contact basin that could lower the wastewater pH from
10.1 to a pH ranging from 6.0-9.0.
DESIGN DESCRIPTION
Neutralization contact basin is used to neutralize the wastewater since it is

basic (10.6). Neutralization is the process of adjusting the pH of water through the
addition of an acid or a base, depending on the target pH and process requirements.
It is made of reinforced concrete and has 4 channels for better contact and treatment.
In every batch of production, a total of 8998.08 kg of wastewater is discharged

from Nutsche Filter 1, 2, and 3 after each process. 107,976.96 kg per 6 days of
wastewater from the production process of tylose powder is needed to be neutralized.
Acidic chemical is added to adjust the pH.

DESIGN SELECTION
A back and forth long channel contact basin is selected due to easy installation
and lower cost, and provides good contact between the wastewater to be treated and
the chemical added.
DESIGN PARTS AND FUNCTIONS
Figure 9.10 Parts of the Neutralizaon Contact Basin
Table 9.14 Parts and Function of the Neutralization Contact Basin

PARTS FUNCTION
Channel This is where the wastewater is contained and treated
This is what separates and makes channels or
Baffle compartment for longer contact of the wastewater with
the chemical.
Inlet Where the wastewater is introduced
Where the treated wastewater is released to the next
Outlet
treatment equipment

DESIGN ASSUMPTIONS
1. The amount of wastewater to be treated in the neutralization tank is

107,976.96 kg per 6 days.
2. The density of wastewater is 1059.06 kg/m3
3. The BOD of wastewater entering is 1699 mg/l
4. The TSS of wastewater entering is 931 mg/l
5. Scheme IIA design for hydraulic performance with four channels will be used.
DESIGN CONSIDERATIONS
1. The material of construction to be used is reinforced concrete. (Metcalf and

Eddy. Wastewater Engineering Treatment and Reuse. page 1272)
2. The safety factor is 20% (Perry, R.H. and Green, D.W. Perry’s Chemical
Engineering Handbook 7th edition)
3. The length to width ratio for contact basins is at least 20:1 (Metcalf and Eddy.
Wastewater Engineering Treatment and Reuse. page 1272)
4. Typical flow of wastewater in Scheme IIA contact basin is 3.61 m3/s (Metcalf
and Eddy. Wastewater Engineering Treatment and Reuse. page 1275)
5. Typical depth of wastewater in Scheme IIA contact basin is 4.33 m (Metcalf and
Eddy. Wastewater Engineering Treatment and Reuse. page 1275)
6. Contact time of wastewater in Scheme IIA contact basin is 31.10 min (Metcalf
and Eddy. Wastewater Engineering Treatment and Reuse. page 1275)
7. Number of channels in Scheme IIA contact basin is 4 (Metcalf and Eddy.
Wastewater Engineering Treatment and Reuse. page 1274)
DESIGN REQUIREMENTS
1. HCl Dosing 5. Channel Width

2. Basin Volume 6. Baffle Width
3. Surface Area
4. Total Width and Length

PAMANTASAN NG LUNGSOD NG MAYNILA
University of the City of Manila
College of Engineering and Technology
Department of Chemical Engineering
DESIGN CALCULATION
1. HCl Dosing
Chemical Reaction for neutralizing the basic wastewater
NaOH + HCl →NaCl + H20
HCL having a concentration of 35.2% with an equivalent weight of 36.5 (Metcalf

and Eddy. Wastewater Engineering Treatment and Reuse. Table 6-15, page
527)
107976.96 𝑘𝑔
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑊𝑊 𝑤𝑖𝑡ℎ 𝑁𝑎𝑂𝐻 = = 101.9555 𝑚3
𝑘𝑔
1059.06 3
𝑚
354.64 𝑘𝑔 + 315.77 𝑘𝑔
𝑚𝑜𝑙𝑒𝑠 𝑠𝑜𝑙𝑢𝑡𝑒 40 𝑘𝑔/𝑚𝑜𝑙𝑒
𝑀𝑜𝑙𝑎𝑟𝑖𝑡𝑦 𝑜𝑓 𝑁𝑎𝑂𝐻 𝑖𝑛 𝑊𝑊 = =
𝐿 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛 1000 𝐿
(101.9555𝑚3 )( )
1 𝑚3
= 0.0002 𝑀
35.2 𝑘𝑔
𝑚𝑜𝑙𝑒𝑠 𝑠𝑜𝑙𝑢𝑡𝑒 36.46 𝑘𝑔/𝑚𝑜𝑙𝑒
𝑀𝑜𝑙𝑎𝑟𝑖𝑡𝑦 𝑜𝑓 𝐻𝐶𝑙 = = = 0.0097 𝑀
𝐿 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛 100 𝑘𝑔 𝐻20 1000 𝐿
( )( )
𝑘𝑔 1 𝑚3
1000 3
𝑚
1000 𝐿 𝑚𝑜𝑙𝑒𝑠
101.9555𝑚3 ( 3
) 𝑥 0.0002 = 20.3911 𝑚𝑜𝑙𝑒𝑠 𝑁𝑎𝑂𝐻
1𝑚 𝐿
Since NaOH:HCl is 1:1,
𝑚𝑜𝑙𝑒𝑠 𝑁𝑎𝑂𝐻 = 𝑚𝑜𝑙𝑒𝑠 𝐻𝐶𝑙
𝑚𝑜𝑙𝑒𝑠 𝐻𝐶𝑙 𝑛𝑒𝑒𝑑𝑒𝑑 𝑡𝑜 𝑛𝑒𝑢𝑡𝑟𝑎𝑙𝑖𝑧𝑒 𝑡ℎ𝑒 𝑊𝑊 = 20.3911 𝑚𝑜𝑙𝑒𝑠 𝐻𝐶𝑙

20.3911 𝑚𝑜𝑙𝑒𝑠 𝐻𝐶𝑙 1𝑚3 𝑘𝑔
= 2102.1753 𝐿 𝐻𝐶𝑙 𝑥 𝑥 1490 3
0.0097 𝑚𝑜𝑙𝑒𝑠/𝐿 1000 𝐿 𝑚
= 3132.2412 𝑘𝑔 𝐻𝐶𝑙
𝑼𝒔𝒆 𝟑, 𝟏𝟑𝟐. 𝟐𝟒 𝒌𝒈𝑯𝑪𝒍 (𝟐. 𝟏𝟎 𝒎𝟑 )

2. Basin Volume
𝑉 = 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑤𝑎𝑠𝑡𝑒𝑤𝑎𝑡𝑒𝑟 + 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝐻𝐶𝑙 𝑎𝑑𝑑𝑒𝑑
𝑉 = 101.9555 𝑚3 + 2.1022 𝑚3 = 104.0577 𝑚3
Applying 20% safety factor:
𝑉 = 104.0577 𝑥 1.20 = 124.8692 𝑚3
𝑼𝒔𝒆 𝟏𝟐𝟓. 𝟎𝟎 𝒎𝟑
3. Surface Area
𝑉 124.8692 𝑚3
𝐴= = = 24.0318 𝑚2
𝐷 4.33 𝑚 𝑥 1.20
𝑼𝒔𝒆 𝟐𝟓. 𝟎𝟎 𝒎𝟐
4. Total Width and Length
𝐴 = 𝐿 𝑥 𝑊 = 20𝑊 𝑥 𝑊 = 21𝑊 2
24.0318𝑚2 = 21𝑊 2
𝑾 = 𝟏. 𝟎𝟔𝟗𝟖 𝒎 = 𝟏. 𝟏𝟎 𝒎
𝑳 = 𝟐𝟏. 𝟑𝟗𝟓𝟏 𝒎 = 𝟐𝟏. 𝟒𝟎 𝒎
5. Channel Width
With 4 channels to be used, the total width must also be divided by 4 to

obtain the channel width.
𝑊𝑇 1.10 𝑚
𝑊𝐶 = = = 0.275 𝑚
4 4
𝑼𝒔𝒆 𝑾𝑪 = 𝟎. 𝟐𝟖 𝒎
𝑼𝒔𝒆 𝑳𝑪 = 𝑳 = 𝟐𝟏. 𝟒𝟎 𝒎
6. Baffle Length
Since Baffle Width is assumed to be 80% of the total basin length,
21.40 𝑚 𝑥 0.80 = 17.12 𝑚
𝑼𝒔𝒆 𝟏𝟕. 𝟐𝟎 𝒎

DESIGN SPECIFICATIONS
NEUTRALIZATION CONTACT BASIN
OPERATING DATA
Number of Units 1
Feed Wastewater from Flow Equalization Tank
Function To neutralize the wastewater to a pH of 7
Material of
Reinforced Concrete
Construction
TECHNICAL DATA
Parameter Proposed
Volume 125 m3
Surface Area 25 m2
Depth 5.20 m
Total Width 1.10 m
Total Length 21.40 m
Channel Width 0.28 m
Channel Length 21.40 m
Baffle Length 17.20 m
SUPPLIER INFORMATION
Company Name Bauer International (Phils) Inc
2nd Floor Regalia Park Tower, 150 P. Tuazon St., Cor.
Company Address
EDSA, Cubao, Quezon City
Phone Number +632 912 4503
Contact Details
Email Address Bauer.international@yahoo.com
DESIGN CONFIGURATION
DESIGN CONFIGURATION OF NEUTRALIZATION CONTACT BASIN


CLARIFIER
Factors to be considered in Designing a Clarifier
The design of a clarifier is concerned with the following considerations:
1. Detention time
2. Surface loading rates
3. Scour velocity
Step-by-Step Procedure in Designing a Clarifier
The step-by-step procedure in designing a clarifier is as follows:
1. Given the influent data (mass and density), solve for the influent volumetric
flow rate of the wastewater. This will be used in the calculation of the volume
requirements for the clarifier.
2. Calculate the capacity of the clarifier using the influent volumetric flowrate.
Apply the safety factor. This shall be used in the calculation of the
dimensions.
3. Calculate the dimensions of the clarifier using the computed capacity.
4. Solve for the detention time using the volume of the wastewater and the
capacity of the clarifier.
5. Compute the removed and retained total suspended solids.
6. Compute the removed and retained BOD.
Clarifier Design
DESIGN PROBLEM
A total of 111,109.20 kg of wastewater is discharged from the pre-treatment

process. Design a clarifier that could reduce the suspended solids (931 mg/L) and the
BOD (1,699 mg/L) content of the wastewater by sedimentation.

DESIGN DESCRIPTION
A clarifier is used to settle the solids from the 111,109.20 kg wastewater

coming from the pre-treatment process. 70% and 30% of the TSS and the BOD will be
removed, respectively.
DESIGN SELECTION
A rectangular clarifier will be used for the design. Rectangular shaped is chosen
over circular because rectangular clarifiers can be built shallower but can achieve the
same effluent quality and subsequently result in cost savings. Also, flow is usually more
even and often requires less head loss in rectangular clarifiers. The even flow
distribution configuration for rectangular clarifiers requires simpler and less expensive
pipe work layout and pumping requirement as compared to circular clarifiers where
the pipes require a more complicated layout pattern and perhaps a separate pumping
station, as well.
PARTS AND FUNCTIONS
FUNCTION
1 Inlet The entry point of the wastewater to the clarifier
2 Sludge Trough The scraped sludge goes here before exiting the clarifier
3 Drive Unit Moves the flight and chain system

Flights are moved by the chain along the bottom of the

4 Drive Chain and Flights clarifier pushing settled solids and across the top to collect
floating solids
5 Scum Trough Collects scum removed by the flight
6 Effluent Weir Provides uniform flow over the surface of the clarifier
7 Outlet This is where the effluent exits
DESIGN ASSUMPTIONS
1. Wastewater entering the clarifier from the previous process is 111,109.20 kg
2. The density of the influent at 25 °C is 1,274.78 kg/m3.
3. The BOD of wastewater entering is 1,699 mg/L
4. The TSS of wastewater entering is 931 mg/L.
1. The material of construction to be used is reinforced concrete (Wastewater

Engineering: Treatment and Reuse, 4th Ed. by Tchobanoglous, et. al., Metcalf
& Eddy, Inc.)
2. The safety factor is 20% (Perry, R.H. and Green, D.W. Perry’s Chemical
Engineering Handbook 7th edition)
3. The typical range of depth of rectangular clarifier is 3.00 - 4.90 m (Wastewater

Engineering: Treatment and Reuse, 4th Ed. by Tchobanoglous, et. al., Metcalf
& Eddy, Inc.). So, 3.00 m deep clarifier is used.
4. The conversion factor of 1.70 lb solids/lb BOD removed is considered for

clarifiers (Mathematics Manual for Water and Wastewater Plant Operators,
Frank R. Spellman, p. 114).

5. The typical design value of detention time is 2.00 - 3.00 hours (Clarifier
Calculations by Michigan Department of Environmental Quality Operator
Training and Certification Unit).
6. The typical design value of surface overflow rate is 400-800 gal/d/ft2 (Clarifier
Calculations by Michigan Department of Environmental Quality Operator
Training and Certification Unit). The assumed surface overflow rate is 600
gal/d/ft2 (24.54 m3/d/m2).
7. The typical efficiency of clarifiers for BOD and TSS are 30% and 70%,
respectively (Handbook of Water and Wastewater Treatment Plant Operations,
Frank R. Spellman)
DESIGN REQUIREMENTS
1. Volume of Wastewater
2. Clarifier Dimensions
3. Detention Time
4. Suspended Solids
5. BOD
6. Total Volume of Effluent
DESIGN CALCULATIONS
1. Volume of Wastewater
𝑚𝑎𝑠𝑠 𝑜𝑓 𝑖𝑛𝑓𝑙𝑢𝑒𝑛𝑡 111,109.20 𝑘𝑔

𝑉= =
𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑖𝑛𝑓𝑙𝑢𝑒𝑛𝑡 1274.78 𝑘𝑔/𝑚3
V = 87.1595 m3/day

𝑉 = 87.1595 𝑥 1.20 = 104.5914 𝑚3
𝑼𝒔𝒆 𝟏𝟎𝟒. 𝟓𝟗𝟏𝟒 𝒎𝟑 /𝒅𝒂𝒚
2. Clarifier Dimensions
Height, Length, Width
𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑤𝑎𝑠𝑡𝑒𝑤𝑎𝑡𝑒𝑟
𝐴𝑟𝑒𝑎 =
𝑜𝑣𝑒𝑟𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒
104.5914 𝑚3
𝐴𝑟𝑒𝑎 = = 4.2621𝑚2
24.54 𝑚3 /𝑚2
𝐴 = 𝐿𝑒𝑛𝑔𝑡ℎ × 𝑊𝑖𝑑𝑡ℎ = 4 (𝑊) × 𝑊
4.2621 𝑚2 = 4𝑊 2
W = 1.0322 m
L = 4(W) = 4(1.0322 m) = 4.1288 m
According to Metcalf and Eddy, typical depth of rectangular clarifier is 3m.

Thus,
H=3m
Use 1.10m x 4.40m x 3.00m
3. Detention Time
𝑇𝑎𝑛𝑘 𝑉𝑜𝑙𝑢𝑚𝑒 (1.10 × 4.40 × 3.00)𝑚3 24 ℎ

𝑇𝑖𝑚𝑒 = = ×
𝑉 (87.1595)𝑚3 /𝑑𝑎𝑦 1 𝑑𝑎𝑦
Detention Time = 3.9982 h
Use 4 hours

4. Suspended Solids
The typical efficiency of clarifiers for TSS is 70% according to the Handbook of Water
and Wastewater Treatment Plant Operations, Frank R. Spellman, page 565
Based from the test results of Mach Union Water Lab., the TSS of the wastewater
sample is,
TSS = 931 mg/L
TSS removed = 0.7(931 mg/L) = 651.7mg/L
TSS retained = (931 – 651.7) = 279.3 mg/L
5. BOD
The typical efficiency of clarifiers for BOD is 30% according to the Handbook of Water
and Wastewater Treatment Plant Operations, Frank R. Spellman, page 565
The computed BOD level at 6th day is,
BOD = 1699 mg/L
BOD removed = 0.3(1699mg/L) = 509.7 mg/L
BOD retained = (1699 - 509.7)mg/L = 1189.3 mg/L
6. Total Volume of Effluent
𝑘𝑔𝑠𝑜𝑙𝑖𝑑
𝑆𝑜𝑙𝑖𝑑𝑠 𝑟𝑒𝑚𝑜𝑣𝑒𝑑 = 44.4252 𝑘𝑔𝐵𝑂𝐷 × 1.7 = 75.5228 𝑘𝑔
𝑘𝑔𝐵𝑂𝐷
Solids removed = 75.5228 kg
Mass effluent = Mass influent – Mass TSS removed - Mass Solids removed

Mass effluent = 111,109.20 – 56.8019 kg – 75.5228 kg
Mass effluent = 110,976.8753 kg
110,976.8753 𝑘𝑔
𝑉=
1274.78 𝑘𝑔/𝑚3
V = 87.0557 m3

CLARIFIER
OPERATING DATA
Number of Units 1
Mode of Operation Batch
Feed 111,109.20 kg wastewater

Function To remove settleable solids and reduce BOD of wastewater
Material of Construction Reinforced Concrete
TECHNICAL DATA
Parameter Proposed Existing
Volume 104.60 m3 -
Surface Area 4.84 m2 -
Depth 3.00 m 3 – 4.9 m
Total Width 1.10 m 3 – 24 m
Total Length 4.40 m 15 – 90 m
Detention Time 4.00 h 2–3h
Surface Overflow rate 24.54 m3/d/m2 16.36 – 107.36 m3/d/m2
Weir Overflow rate 79.24 m3/d/m 124.67 m3/d/m
EFFLUENT DATA
Mass 110,976.8753 kg
BOD 1189.3 mg/L
TSS 279.3 mg/L
COD 883352 mg/L
Sludge Removed 132.3247 kg
Company Name Bauer International (Phils) Inc.
2nd Floor Regalia Park Tower, 150 P. Tuazon St., Cor. EDSA, Cubao,
Company Address
Quezon City
Phone Number +632 912 4503
Contact Details
Email Address bauer.international@yahoo.com

CLARIFIER

UPFLOW ANAEROBIC SLUDGE BLANKET REACTOR 1

Factors to be considered in Designing an Upflow Anaerobic Sludge Blanket Reactor
The design of a UASB is concerned with the following considerations:
1. Upflow velocity
2. Sludge Production
3. Methane Production
4. Effluent Characteristics
Step-by-Step Procedure in Designing a UASB Reactor
1. Given the influent data (mass and density), solve for the influent volumetric flow
rate of the wastewater. This will be used in the calculation of the volume
requirements for the UASB reactor.
2. Calculate the capacity of the UASB reactor using the influent volumetric
flowrate. Apply the safety factor. This shall be used in the calculation of the
dimensions.
3. Calculate the dimensions of the UASB reactor using the computed capacity.
4. Calculate for the volume of the sludge recovered from the reactor.
5. Calculate the amount of methane gas produced in the reactor per day.
6. Compute the removed and retained COD.

UASB Reactor Design
DESIGN PROBLEM
110,976.8753 kg of wastewater discharged from the clarifier. Design a reactor

which can decrease the 88352 mg/L COD content of the wastewater through sludge
removal.
DESIGN DESCRIPTION
UASB is an anaerobic wastewater treatment process, forming a blanket of

granular sludge that suspends in the reactor. The effluent wastewater flows upwards
through the blanket and is biodegraded by an active anaerobic consortium, held under
suspension.
DESIGN SELECTION
The UASB Reactor was selected to lower the COD of the wastewater. It was
chosen because of allows the use of high volumetric COD loadings compared to other
anaerobic process.
PARTS AND FUNCTIONS

PARTS FUNCTION
Primary Clarifier Removal/entrapment of (non)biodegradable suspended
solids from the influent
Biological reactors Removal of biodegradable organic compounds by
converting them into methane. (main UASB reactor)
Secondary clarifier Clarifying the treated effluent in the settler zone at the top
part of the UASB reactor
Sludge digester Stabilisation (digestion) and improving the dewatering
characteristics of the retained influent primary sludge
DESIGN ASSUMPTIONS
1. The amount of wastewater to be treated in the UASB is 110,976.8753 kg per

6 days.
3. The BOD of wastewater entering is 103.6588 kg/day
4. The COD of wastewater entering is 88352 mg/L
1. Dimensions of the reactor or the Main UASB tank, shape of tank is rectangular
for large scale.
2. Assume 4 hours of hydraulic retention time (Wastewater Treatment and Reuse

(Metcalf & Eddy, 4th ed, pg 1009)
3. Length to width ration is 2:1.
4. The maximum amount of methane that the UASB can produce can be estimated
by multiplying BOD by the maximum methane producing capacity of the
wastewater (B0). The default B0 value for wastewater is 0.6 kg CH4/kg BOD,

as shown in the 2006 IPCC Guidelines for National Greenhouse Gas

Inventories, Volume 5, Chapter 6, Table 6.2.
5. The CH4 producing potential of a specific system is represented by a parameter

known as the methane conversion factor (MCF). This value ranges from 10-20
percent for Institutional wastewater.
6. The slope of the settler bottom (1.e. the inclined wall of the gas collector) should
be between 45-60°
7. The surface area of the apertures between the gas collectors should be 15-20%
of the reactor surface area.
8. The height of the gas collector should be between 1.5-2m at reactor heights of
5-7m.
9. To facilitate the release and collection of gas bubbles and to combat scum layer
formation, a liquid-gas interface should be maintained in the gas collector.
10. To avoid up-flowing gas bubbles to enter the settle compartment, the overlap
of the baffles installed beneath the apertures should be 10-20cm.
11. Generally, scum layer baffles should be installed at the effluent weirs.
12. The diameter of the gas exhaust pipes should be sufficient to guarantee the
easy removal of the biogas from the gas collection cap, particularly in case
foaming.
13. In the upper part of the gas cap, anti-foam spray nozzles should be installed in
the case of the treatment of the waste water is accompanied by heavy foaming.
14. The removal efficiency for COD of UASB reactor is 95% (Metcalf & Eddy, 4th ed,
pg 1007).

15. The soluble COD accounts for over 80% of the total COD (Eremektar et. Al,
2005).
DESIGN REQUIREMENTS
1. Reactor Volume
2. Height of the Tank
3. Length and Width of the Tank
4. Volume of Sludge
5. Methane gas production
6. Estimating the effluent COD
DESIGN CALCULATIONS
a. Reactor Volume
𝑉𝑟 = 𝐻𝑅𝑇 𝑥 𝑄
Where: Q = rate of sewage input to the reactor
HRT = hydraulic retention time
Vr = volume of main reactor
𝑚3
𝑉𝑟 = 4 ℎ𝑟𝑠 𝑥 3.6273
ℎ𝑟
𝑉𝑟 = 14.51 𝑚3
𝑉𝑟 = 14.51 𝑚3 𝑥 1.20 = 17.412 𝑚3
𝑼𝒔𝒆 𝟏𝟕. 𝟒𝟏 𝒎𝟑
b. Height of the Tank
𝐻 = 𝐻𝑠 + 𝐻𝑠𝑒
Where: H = height of the tank
Hs = height of sludge layer area (main reactor)

Hse = height of the sedimentation area (sludge layer height)

𝐻𝑠 = 𝑉𝑥𝐻𝑅𝑇
Since the soluble COD accounts for over 80% of the total COD (Eremektar et. Al, 2005),
from table 3 use V (liquid upflow velocity) = 1.5 m / hr
Table 9.17 (Metcalf and Eddy, Table 10-14)
Upflow Velocity, m/hr Reactor Height, m
Wastewater type Range Typical Range Typical
COD nearly 100% 1.0 – 3.0 1.5 6 – 10 8
sluble
COD partially 1.0 – 1.0 3–7 6
soluble 1.25
Domestic 0.8 – 10 0.7 3–6 5
Wastewater
1.5𝑚
𝐻𝑠 = 𝑥 4ℎ𝑟𝑠 = 6𝑚
ℎ𝑟
For Hse use the table below.
Table 9.18 (Velasquez, et. Al,2014)
COD input Sludge Layer Height
< 3000 mg / L 3–5m
> 3000 mg / L 5–7m
Use Hse = 5 m
𝐻 = 6𝑚 + 5𝑚 = 11𝑚
𝑼𝒔𝒆 𝑯 = 𝟏𝟏𝒎
c. Length and Width of the Tank
Use the ratio L: W= 2: 1

Since Vr = L x W x H; L = 2W
17.412 𝑚3 = 2𝑊 2 𝑥 11𝑚

𝑊 = 0.8896 𝑚
𝑼𝒔𝒆 𝑾 = 𝟎. 𝟗𝟎 𝒎
𝐿 = 2 𝑥 0.90 𝑚
𝑼𝒔𝒆 𝑳 = 𝟏. 𝟖𝟎 𝒎
d. Volume of Sludge
From the dimension of the main reactor, the height of the sedimentation area or the
sludge layer height is 5m.
𝑉𝑠 = 𝐿 𝑥 𝑊 𝑥 𝐻𝑠𝑒
𝑉𝑠 = 1.80𝑚 𝑥 0.90𝑚 𝑥 5𝑚 = 8.1𝑚3
The amount of sludge that can be extracted from the tank is only 30-50 % of its volume,
use 30%.
𝑉𝑠 = 8.1𝑚3 𝑥 0.30 = 2.43 𝑚3
𝑼𝒔𝒆 𝑽𝒔 = 𝟐. 𝟒𝟑 𝒎𝟑
e. Methane Gas Production

The equations proposed to calculate CH4 generation at wastewater treatment systems
are presented below:
𝐶𝐻4 = 𝛴𝑚𝑜𝑛𝑡ℎ (𝐹𝑙𝑜𝑤 𝑥 𝐵𝑂𝐷 𝑥 𝐵0 𝑥 𝑀𝐶𝐹)
Where:
CH4 = Monthly CH4 mass emissions from the UASB reactor (kg/month).
Flow = Monthly flow treated through UASB treatment system (m3/month).
BOD = Average monthly organics loading in wastewater entering UASB treatment
system (kg/m3).
B0 = Maximum CH4 producing potential of institutional wastewater (default value of
0.6 kg CH4/kg BOD).
MCF = CH4 conversion factor, indicating the extent to which the organic content
(measured as BOD) degrades anaerobically.

𝑚3 ℎ𝑟𝑠 𝑑𝑎𝑦𝑠
𝐹𝑙𝑜𝑤 = 3.6273 × 5%( 𝑐𝑜𝑛𝑣𝑒𝑟𝑡𝑒𝑑 𝑖𝑛𝑡𝑜 𝑏𝑖𝑜𝑚𝑎𝑠𝑠) × 24 × 30
ℎ𝑟 𝑑𝑎𝑦 𝑚𝑜𝑛𝑡ℎ
𝑚3
= 130.58
𝑚𝑜𝑛𝑡ℎ
𝑘𝑔 1 1𝑑𝑎𝑦
𝐵𝑂𝐷 = 103.6588 × × = 1.1907 𝑘𝑔/𝑚3
𝑑𝑎𝑦 𝑚3 24ℎ𝑟𝑠
3.6273
ℎ𝑟
𝑘𝑔𝐶𝐻4
𝐵0 = 0.6
𝑀𝐶𝐹 = 10%
𝑚3 𝑘𝑔𝐶𝐻4
𝐶𝐻4 = 𝛴𝑚𝑜𝑛𝑡ℎ (130.58 × 1.1907 𝑘𝑔/𝑚3 × 0.6 × 0.10)
𝑚𝑜𝑛𝑡ℎ 𝑘𝑔𝐵𝑂𝐷
CH4 = 9.33 kg/month = 0.311 kg/day
Methane Gas collection system is no longer in our capacity to design but we may
compute for the volume of methane produced per month.
W=PxV
Where: W= weight of methane
P = density of methane (0.66kg/ m3)
V = volume of methane (m3/month)
𝑘𝑔 0.66𝑘𝑔
9.33 = 𝑥𝑉
𝑚𝑜𝑛𝑡ℎ 𝑚3
𝑚3
𝑉 = 14.1364
𝑚𝑜𝑛𝑡ℎ
𝒎𝟑
𝑼𝒔𝒆 𝑽 = 𝟏𝟒. 𝟏𝟒
𝒎𝒐𝒏𝒕𝒉
6.Mass of COD removed
Calculate the amount of COD retained
𝐶𝑂𝐷𝑒𝑓𝑓𝑙𝑢𝑒𝑛𝑡 = 𝐶𝑂𝐷𝑖𝑛𝑓𝑙𝑢𝑒𝑛𝑡 (1 − 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦)
𝑚𝑔
𝐶𝑂𝐷𝑒𝑓𝑓𝑙𝑢𝑒𝑛𝑡 = 88352 (1 − 0.95)
𝐿
𝒎𝒈
𝑪𝑶𝑫𝒆𝒇𝒇𝒍𝒖𝒆𝒏𝒕 = 𝟒𝟒𝟏𝟕. 𝟔
𝑳

To calculate the amount of COD removed:

𝑀𝐶𝑂𝐷 = 𝐶𝑂𝐷𝑖𝑛𝑓𝑙𝑢𝑒𝑛𝑡 − 𝐶𝑂𝐷𝑒𝑓𝑓𝑙𝑢𝑒𝑛𝑡
𝑚𝑔 𝑚𝑔 1𝑘𝑔 1000𝐿 87.06𝑚3
𝑀𝐶𝑂𝐷 = (88352 − 4417.6 )( ) ( )( )
𝐿 𝐿 1𝑥106 𝑚𝑔 1𝑚3 𝑑𝑎𝑦
𝑴𝑪𝑶𝑫 = 𝟕𝟑𝟎𝟕. 𝟑𝟑 𝒌𝒈/𝒅𝒂𝒚
𝐸𝑓𝑓𝑙𝑢𝑒𝑛𝑡 = 𝑖𝑛𝑓𝑙𝑢𝑒𝑛𝑡 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 − 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐶𝑂𝐷 𝑟𝑒𝑚𝑜𝑣𝑒𝑑
Mass effluent = 110,976.88 – 7307.33 kg
Effluent = 103,669.55 kg
UASB 1
OPERATING DATA
Number of Units 1
Feed Wastewater from clarifier

Function To reduce the COD of the wastewater
TECHNICAL DATA
Volume 17.41m3 -
Height 11 m 5 – 20 m
Detention Time 4.00 h 4-9 h
EFFLUENT DATA
Mass 103,669.55 kg
BOD 1189.3 mg/L
TSS 279.3 mg/L
COD 4417.6 mg/L
Methane Gas Produced 9.33 kg/month
Sludge Volume 2.43 m3
Company Name BONGAR ENVIROSYSTEMS TECHNOLOGIES, CORP.

310 Pilar Road, Almanza I

Company Address
Las Pinas City, Philippines, 1750
Phone Number (+632) 8013943
Contact Details
Email Address imbongar@yahoo.com
UASB REACTOR 1

UPFLOW ANAEROBIC SLUDGE BLANKET REACTOR 2

Factors to be considered in Designing an Upflow Anaerobic Sludge Blanket Reactor
The design of a UASB is concerned with the following considerations:
1. Upflow velocity
2. Sludge Production
3. Methane Production
4. Effluent Characteristics
Step-by-Step Procedure in Designing a UASB Reactor
1. Given the influent data (mass and density), solve for the influent volumetric
flow rate of the wastewater. This will be used in the calculation of the volume
requirements for the UASB reactor.
2. Calculate the capacity of the UASB reactor using the influent volumetric
flowrate. Apply the safety factor. This shall be used in the calculation of the
dimensions.
3. Calculate the dimensions of the UASB reactor using the computed capacity.
4. Calculate for the volume of the sludge recovered from the reactor.
5. Calculate the amount of methane gas produced in the reactor per day.
6. Compute the removed and retained COD.
UASB Reactor Design

DESIGN PROBLEM
103,669.55 kg of wastewater discharged from the first UASB reactor. Design a

reactor which can decrease the COD content of the wastewater through sludge
removal.

DESIGN DESCRIPTION
UASB is an anaerobic wastewater treatment process, forming a blanket of granular

sludge that suspends in the reactor. The effluent wastewater flows upwards through
the blanket and is biodegraded by an active anaerobic consortium, held under
suspension.
DESIGN SELECTION
The UASB Reactor was selected to lower the COD of the wastewater. It was chosen
because of allows the use of high volumetric COD loadings compared to other
anaerobic process.
PARTS AND FUNCTIONS
PARTS FUNCTION
Primary Clarifier Removal/entrapment of (non)biodegradable suspended
solids from the influent
Biological reactors Removal of biodegradable organic compounds by
converting them into methane. (main UASB reactor)
Secondary clarifier Clarifying the treated effluent in the settler zone at the top
part of the UASB reactor

Sludge digester Stabilisation (digestion) and improving the dewatering

characteristics of the retained influent primary sludge
DESIGN ASSUMPTIONS
1. The amount of wastewater to be treated in the UASB is 103,669.55 kg
3. The BOD of wastewater entering is 103.6588 kg/day
4. The COD of wastewater entering is 4417.6 mg/l
1. Dimensions of the reactor or the Main UASB tank, shape of tank is

rectangular for large scale.
2. Assume 4 hours of hydraulic retention time (Wastewater Treatment and

Reuse (Metcalf & Eddy, 4th ed, pg 1009)
3. Length to width ration is 2:1.
4. The maximum amount of methane that the UASB can produce can be
estimated by multiplying BOD by the maximum methane producing capacity
of the wastewater (B0). The default B0 value for wastewater is 0.6 kg
CH4/kg BOD, as shown in the 2006 IPCC Guidelines for National
Greenhouse Gas Inventories, Volume 5, Chapter 6, Table 6.2.
5. The CH4 producing potential of a specific system is represented by a

parameter known as the methane conversion factor (MCF). This value
ranges from 10-20 percent for Institutional wastewater.
6. The slope of the settler bottom (1.e. the inclined wall of the gas collector)
should be between 45-60°

7. The surface area of the apertures between the gas collectors should be 15-
20% of the reactor surface area.
8. The height of the gas collector should be between 1.5-2m at reactor heights
of 5-7m.
9. To facilitate the release and collection of gas bubbles and to combat scum
layer formation, a liquid-gas interface should be maintained in the gas
collector.
10. To avoid up-flowing gas bubbles to enter the settle compartment, the
overlap of the baffles installed beneath the apertures should be 10-20cm.
11. Generally, scum layer baffles should be installed at the effluent weirs.
12. The diameter of the gas exhaust pipes should be sufficient to guarantee the
easy removal of the biogas from the gas collection cap, particularly in case
foaming.
13. In the upper part of the gas cap, anti-foam spray nozzles should be installed
in the case of the treatment of the waste water is accompanied by heavy
foaming.
14. The removal efficiency for COD of UASB reactor is 95% (Metcalf & Eddy, 4th
ed, pg 1007).
15. The soluble COD accounts for over 80% of the total COD (Eremektar et. Al,
2005).
DESIGN REQUIREMENTS
1. Reactor Volume

4. Volume of Sludge
5. Methane gas production
6. Estimating the effluent COD
DESIGN CALCULATIONS
1. Reactor Volume
𝑉𝑟 = 𝐻𝑅𝑇 𝑥 𝑄
Where: Q = rate of sewage input to the reactor
HRT = hydraulic retention time
Vr = volume of main reactor
𝑚3
𝑉𝑟 = 4 ℎ𝑟𝑠 𝑥 3.3885
ℎ𝑟
𝑉𝑟 = 13.55 𝑚3
𝑉𝑟 = 13.55 𝑚3 𝑥 1.20 = 16.26 𝑚3
𝑼𝒔𝒆 𝟏𝟔. 𝟐𝟔 𝒎𝟑
𝐻 = 𝐻𝑠 + 𝐻𝑠𝑒
Where: H = height of the tank
Hs = height of sludge layer area (main reactor)
Hse = height of the sedimentation area (sludge layer height)
𝐻𝑠 = 𝑉𝑥𝐻𝑅𝑇
Since the soluble COD accounts for over 80% of the total COD (Eremektar et. Al,
2005), from table 3 use V (liquid upflow velocity) = 1.5 m / hr
Table 9.20 (Metcalf and Eddy, Table 10-14)
Upflow Velocity, m/hr Reactor Height, m
Wastewater type Range Typical Range Typical

COD nearly 100% 1.0 – 3.0 1.5 6 – 10 8

sluble
COD partially 1.0 – 1.25 1.0 3–7 6
soluble
Domestic 0.8 – 10 0.7 3-6 5
Wastewater
1.5𝑚
𝐻𝑠 = 𝑥 4ℎ𝑟𝑠 = 6𝑚
ℎ𝑟
For Hse use the table below.
Table 9.21 (Velasquez, et. Al,2014)
COD input Sludge Layer Height
< 3000 mg / L 3–5m
> 3000 mg / L 5–7m
Use Hse = 5 m
𝐻 = 6𝑚 + 5𝑚 = 11𝑚
𝑼𝒔𝒆 𝑯 = 𝟏𝟏𝒎
Use the ratio L: W= 2: 1

Since Vr = L x W x H; L = 2W
16.26 𝑚3 = 2𝑊 2 𝑥 11𝑚
𝑊 = 0.8597 𝑚
𝑼𝒔𝒆 𝑾 = 𝟎. 𝟖𝟔 𝒎
𝐿 = 2 𝑥 0.86 𝑚
𝑼𝒔𝒆 𝑳 = 𝟏. 𝟕𝟐 𝒎
4. Volume of Sludge
From the dimension of the main reactor, the height of the sedimentation area or the
sludge layer height is 5m.

𝑉𝑠 = 𝐿 𝑥 𝑊 𝑥 𝐻𝑠𝑒
𝑉𝑠 = 1.72𝑚 𝑥 0.86𝑚 𝑥 5𝑚 = 7.40𝑚3
The amount of sludge that can be extracted from the tank is only 30-50 % of its
volume, use 30%.
𝑉𝑠 = 7.40 𝑚3 𝑥 0.30 = 2.22 𝑚3
𝑼𝒔𝒆 𝑽𝒔 = 𝟐. 𝟐𝟐 𝒎𝟑
5. Methane Gas Production
The equations proposed to calculate CH4 generation at wastewater treatment systems
are presented below:
𝐶𝐻4 = 𝛴𝑚𝑜𝑛𝑡ℎ (𝐹𝑙𝑜𝑤 𝑥 𝐵𝑂𝐷 𝑥 𝐵0 𝑥 𝑀𝐶𝐹)
Where:
CH4 = Monthly CH4 mass emissions from the UASB reactor (kg/month).
Flow = Monthly flow treated through UASB treatment system (m3/month).
BOD = Average monthly organics loading in wastewater entering UASB treatment
system (kg/m3).
B0 = Maximum CH4 producing potential of institutional wastewater (default value of
0.6 kg CH4/kg BOD).
MCF = CH4 conversion factor, indicating the extent to which the organic content
(measured as BOD) degrades anaerobically.
𝑚3 ℎ𝑟𝑠 𝑑𝑎𝑦𝑠
𝐹𝑙𝑜𝑤 = 3.3885 × 5%( 𝑐𝑜𝑛𝑣𝑒𝑟𝑡𝑒𝑑 𝑖𝑛𝑡𝑜 𝑏𝑖𝑜𝑚𝑎𝑠𝑠) × 24 × 30
ℎ𝑟 𝑑𝑎𝑦 𝑚𝑜𝑛𝑡ℎ
𝑚3
= 121.99
𝑚𝑜𝑛𝑡ℎ
𝑘𝑔 1 1𝑑𝑎𝑦
𝐵𝑂𝐷 = 103.6588 𝑥 𝑥 = 1.27 𝑘𝑔/𝑚3
𝑑𝑎𝑦 𝑚3 24ℎ𝑟𝑠
3.3885
ℎ𝑟
𝑘𝑔𝐶𝐻4
𝐵0 = 0.6
𝑀𝐶𝐹 = 10%
𝑚3 𝑘𝑔𝐶𝐻4
𝐶𝐻4 = 𝛴𝑚𝑜𝑛𝑡ℎ (121.99 × 1.27 𝑘𝑔/𝑚3 × 0.6 × 0.10)
𝑚𝑜𝑛𝑡ℎ 𝑘𝑔𝐵𝑂𝐷

CH4 = 9.30 kg/month = 0.310 kg/day

Methane Gas collection system is no longer in our capacity to design but we may
compute for the volume of methane produced per month.
W=PxV
Where: W= weight of methane
P = density of methane (0.66kg/ m3)
V = volume of methane (m3/month)
𝑘𝑔 0.66𝑘𝑔
9.30 = 𝑥𝑉
𝑚𝑜𝑛𝑡ℎ 𝑚3
𝑚3
𝑉 = 14.0909
𝑚𝑜𝑛𝑡ℎ
𝒎𝟑
𝑼𝒔𝒆 𝑽 = 𝟏𝟒. 𝟏𝟎
𝒎𝒐𝒏𝒕𝒉
6.Mass of COD removed
Calculate the amount of COD retained
𝐶𝑂𝐷𝑒𝑓𝑓𝑙𝑢𝑒𝑛𝑡 = 𝐶𝑂𝐷𝑖𝑛𝑓𝑙𝑢𝑒𝑛𝑡 (1 − 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦)
𝑚𝑔
𝐶𝑂𝐷𝑒𝑓𝑓𝑙𝑢𝑒𝑛𝑡 = 4417.6 (1 − 0.95)
𝐿
𝒎𝒈
𝑪𝑶𝑫𝒆𝒇𝒇𝒍𝒖𝒆𝒏𝒕 = 𝟐𝟐𝟎. 𝟖𝟖
𝑳
To calculate the amount of BOD removed:
𝑀𝐶𝑂𝐷 = 𝐶𝑂𝐷𝑖𝑛𝑓𝑙𝑢𝑒𝑛𝑡 − 𝐶𝑂𝐷𝑒𝑓𝑓𝑙𝑢𝑒𝑛𝑡
𝑚𝑔 𝑚𝑔 1𝑘𝑔 1000𝐿 81.32𝑚3
𝑀𝐶𝑂𝐷 = (4417.6 − 220.88 )( ) ( )( )
𝐿 𝐿 1𝑥106 𝑚𝑔 1𝑚3 𝑑𝑎𝑦
𝑴𝑪𝑶𝑫 = 𝟑𝟒𝟏. 𝟐𝟖 𝒌𝒈/𝒅𝒂𝒚
𝐸𝑓𝑓𝑙𝑢𝑒𝑛𝑡 = 𝑖𝑛𝑓𝑙𝑢𝑒𝑛𝑡 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 − 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐶𝑂𝐷 𝑟𝑒𝑚𝑜𝑣𝑒𝑑
Mass effluent = 103,669.55 kg – 341.28 kg
Effluent = 103,328.27 kg

UASB 2
OPERATING DATA
Number of Units 1
Feed Wastewater from UASB 1
Function To reduce the COD of the wastewater
TECHNICAL DATA
Volume 16.26 m3 -
Height 11 m 5 – 20 m
Detention Time 4.00 h 4-9 h
EFFLUENT DATA
Mass 103,328.27 kg
BOD 1189.3 mg/L
TSS 279.3 mg/L
COD 220.88 mg/L
Methane Gas Produced 9.30 kg/month
Sludge Volume 2.22 m3
Company Name BONGAR ENVIROSYSTEMS TECHNOLOGIES, CORP.
310 Pilar Road, Almanza I
Company Address
Las Pinas City, Philippines, 1750
Phone Number (+632) 8013943
Contact Details
Email Address imbongar@yahoo.com

UASB REACTOR 2

SECONDARY WASTEWATER TREATMENT

Secondary treatment depends on biological processes to further reduce the
suspended and dissolved solids, which are remaining in the liquid effluent after
primary treatment (Patel & Vashi, 2015).
Levels of Secondary Wastewater Treatment
Treatment Level Description
Secondary Removal of biodegradable organic matter (in
solution or suspension) and suspended solids.
Disinfection is also typically included in the
definition of conventional secondary treatment
Secondary with nutrient removal Removal of biodegradable organics, suspended
solids, and nutrients (nitrogen, phosphorus, or
both nitrogen and phosphorus)
Source: Table 1-4: Levels of Wastewater Treatment, p. 11 (Wastewater Engineering:
Treatment and Reuse, 4th Ed. by Tchobanoglous, et. al., Metcalf & Eddy, Inc.)
Generally, the objective of biological wastewater treatment is to remove or

reduce the concentration of organic and inorganic compounds. The overall objectives
are:
1. To transform (i.e., oxidize) dissolved and particulate biodegradable constituents
into acceptable end-products
2. To capture and incorporate suspended and non-settleable colloidal solids into
a biological floc or biofilm
3. To transform or remove nutrients, such as nitrogen and phosphorus; and, in
some cases
4. To remove specific trace organic constituents and compounds
Definitions of Common Terminology Used for Biological Wastewater Treatment

Term Definition
Metabolic Aerobic Biological treatment processes that occur in the
Function Processes presence of oxygen
Anaerobic Biological treatment processes that occur in the
Processes absence of oxygen
Anoxic The process by which nitrate nitrogen is converted
Processes biologically to nitrogen gas in the absence of oxygen.
This process is also known as denitrification

Facultative Biological treatment processes in which the

Processes organisms can function in the presence or absence
of molecular oxygen
Combined Various combinations of aerobic, anoxic, and
Processes anaerobic processes grouped together to achieve a
specific treatment objective
Treatment Suspended- Biological treatment processes in which the
Processes Growth microorganisms responsible for the conversion of
Processes the organic matter or other constituents in the
wastewater to gases and cell tissue are maintained
in suspension within the liquid
Attached- Biological treatment processes in which the
Growth microorganisms responsible for the conversion of
Processes the organic matter or other constituents in the
wastewater to gases and cell tissue are attached to
some inert medium, such as rocks, slag, or specially
designed ceramic or plastic materials. Attached
growth treatment processes are also known as fixed-
film processes
Combined Term used to describe combined processes (e.g.,
Processes combined suspended and attached growth
processes)
Lagoon A generic term applied to treatment processes that
Processes take place in ponds or lagoons with various aspect
ratios and depths
Treatment Biological The term applied to the removal of nitrogen and
Functions Nutrient phosphorus in biological treatment processes
Removal
Biological The term applied to the biological removal of
Phosphorus phosphorus by accumulation in biomass and
Removal subsequent solids separation
Carbonaceous Biological conversion of the carbonaceous organic
BOD Removal matter in wastewater to cell tissue and various
gaseous end products In the conversion, it is
assumed that the nitrogen present in the various
compounds is converted to ammonia
Nitrification The two-step biological process by which ammonia is
converted first to nitrite and then to nitrate

DenitrificationThe biological process by which nitrate is reduced to

nitrogen and other gaseous end products
Stabilization The biological process by which the organic matter in
the sludges produced from the primary settling and
biological treatment of wastewater is stabilized,
usually by conversion to gases and cell tissue.
Depending on whether this stabilization is carried
out under aerobic or anaerobic conditions, the
process is known as aerobic or anaerobic digestion
Substrate The term used to denote the organic matter or
nutrients that are converted during biological
treatment or that may be limiting in biological
treatment. For example, the carbonaceous organic
matter in wastewater is referred to as the substrate
that is converted during biological treatment
Source: Table 7-1: Definitions of Common Terminology Used for Biological
Wastewater Treatment, p. 550 (Wastewater Engineering: Treatment and Reuse, 4th
Ed. by Tchobanoglous, et. al., Metcalf & Eddy, Inc.)
Unit Operations and Processes Used to Remove Constituents found in Wastewater

Constituent Unit Operation or Process
Biodegradable Organics ✓ Aerobic suspended growth variations
✓ Aerobic attached growth variations
✓ Anaerobic suspended growth variations
✓ Anaerobic attached growth variations
✓ Lagoon variations
✓ (Physical-chemical systems)
✓ (Chemical oxidation)
✓ (Advanced oxidation)
✓ Membrane filtration
Nutrients Nitrogen ✓ [Chemical oxidation (breakpoint chlorination)]
✓ Suspended-growth nitrification and denitrificotion
variations
✓ Fixed-film nitrification and denitrification variations
✓ (Air stripping)
✓ (Ion exchange)
Phosphorus ✓ (Chemical treatment)
✓ Biological phosphorus removal
Nitrogen and ✓ Biological nutrient removal
Phosphorus

Source: Table 1-5: Unit Operations and Processes Used to Remove Constituents
found in Wastewater, p. 13 (Wastewater Engineering: Treatment and Reuse, 4th Ed.
by Tchobanoglous, et. al., Metcalf & Eddy, Inc.)
Major Biological Treatment Processes Used for Wastewater Treatment

Type Common Name Use
Aerobic Suspended Activated Sludge Carbonaceous BOD removal,
Processes Growth Processes Nitrification
Aerated Lagoons Carbonaceous BOD removal,
Nitrification
Aerobic Digestion Stabilization, Carbonaceous BOD
removal
Attached Trickling Filters Carbonaceous BOD removal,
Growth Nitrification
Rotating Biological Carbonaceous BOD removal,
Contactors Nitrification
Packed-Bed Carbonaceous BOD removal,
Reactors Nitrification
Anoxic Suspended Suspended-Growth Denitrification
Processes Growth Denitrification
Attached Attached Growth Denitrification
Growth Denitrification
Anaerobic Suspended Anaerobic Contact Carbonaceous BOD removal
Processes Growth Processes
Anaerobic Stabilization, Solids destruction,
Digestion Pathogen kill
Attached Anaerobic Packed Carbonaceous BOD removal,
Growth and Fluidized Bed Waste stabilization, Denitrification
Sludge Upflow Anaerobic Carbonaceous BOD removal,
Blanket Sludge Blanket especially High-strength wastes
Lagoon Aerobic Aerobic Lagoons Carbonaceous BOD removal
Processes Lagoons
Maturation Maturation Carbonaceous BOD removal,
(tertiary) (tertiary) Lagoons Nitrification
Lagoons
Facultative Facultative Carbonaceous BOD removal
Lagoons Lagoons

Anaerobic Anaerobic Lagoons Carbonaceous BOD removal,

Lagoons Waste stabilization
Source: Table 7-2: Major Biological Treatment Processes Used for Wastewater
Treatment, p. 552 (Wastewater Engineering: Treatment and Reuse, 4th Ed. by
Tchobanoglous, et. al., Metcalf & Eddy, Inc.)
According to the Water Science Glossary of Terms (2016) by the U.S.

Geological Survey, trickling filters and activated sludge are two of the most common
means of secondary treatment.
TRICKLING FILTER
Factors to Consider in Designing a Trickling Filter
In the design of the trickling filter, consideration must be given to:
1. Hydraulic loading rate
2. BOD of influent feed
3. Depth of settling tank
4. Recirculation ratio
5. Needs for establishment of nitrifying bacteria
6. Types of filter bed to use
7. Ventilation system, either forced air or natural
Loading rate is one of the important aspects to consider before you come up
with your trickling filter design. In order to optimize on efficiency, there should be a
continuous growth of biomass to maintain a well-balanced system.
Selection of filter media for your trickle filters must consist of material with high
surface area to allow water to pass through freely without clogging. Typical packing
can either be rock, redwood, plastic vertical flow plate and each media have different
costs consideration and durability in mind.
Air flow is another fundamental aspect towards successful operation of the filter.
The driving force in an open system is draft plus natural wind. If the incoming
wastewater temperature is lower than ambient air, then air will flow towards
downward direction, which in terms of mass transfer factor, this is considered more
economical.
Step-by-Step Procedure in Designing a Trickling Filter

The step-by-step procedure in designing a trickling filter listed below is based

on Wastewater Engineering: Treatment and Reuse, 4th Ed. by Tchobanoglous, et. al.,
Metcalf & Eddy, Inc.
1. Establish influent wastewater characteristics and effluent requirements –
BOD, COD, and TSS.
2. Compute the influent wastewater flowrate per day. This will be used in the
surface area calculation.
3. Determine the treatability constant and the surface area of the trickling filter.
4. Solve for the flow of wastewater applied to the trickling filter per unit of surface
area as well as the organic loading rate.
5. Calculate the residence time of the wastewater in the trickling filter.
6. Using the equation for Spulkraft flushing intensity (SK) to solve for the
rotational speed of the distributor arms.
7. Determine the mass and volume of the effluent as well as its properties by
calculating the mass of BOD removed.
8. Calculate the power requirement.
Actual Design of a Trickling Filter

Design Problem
103,328.27 kg of wastewater per 6 days of operation from the production
process of tylose powder that enters per batch is to be treated in a trickling filter.
Design a trickling filter that will bring the BOD of the wastewater from 1189.3 mg/L
to 118.93 mg/L.
Design Description
Trickling filter is an attached-growth type of process in which microorganisms
attached to a medium are used for removing organic matter from wastewater.
Trickling filter uses packing medium over which the wastewater is distributed. A
rotary distribution mechanism distributes wastewater from the top of the filter
percolating it through the interstices of the film-covered medium. The oxygen
required for organic degradation is supplied by air circulating through the filter.
The trickling filter treatment process occurs through the biological degradation
of organic material by bacteria and micro-organisms contained in the zoogleal film on
the filter media. As the wastewater moves through the filter, the organic matter is

adsorbed onto the film and degraded by a mixed population of aerobic

microorganisms. The microorganisms used are mainly facultative bacteria that
decompose the organic material in the wastewater along with aerobic and anaerobic
bacteria. It includes Achromobacter, Flavobacterium, Psudomonas, and alcaligenes.
Design Selection
A trickling filter is selected to reduce the BOD content of wastewater from
1,189.3 mg/L to 118.93 mg/L through the biological degradation of organic material
by bacteria and micro-organisms contained on the filter media. Trickling filter is
chosen since it has low initial cost, low operating and maintenance costs, and has a
relatively simple operation; thus, providing good performance with minimal operator
care and few energy requirements.
Parts and Functions
PARTS FUNCTION
This provides a surface for the biological slime layer to
Filter Media
attach and grow.
Provides even distribution of wastewater over the
Distributor Arms
media.
Distributor Support Provides support for the distribution system
Inlet Where the wastewater influent is introduced

Where the treated wastewater is released to the next

Outlet
treatment equipment
Design Assumption
1. The influent to be treated is 103,328.27 kg.
2. The influent density is 1274.78 kg/m3.
3. The influent BOD is 1189.3 mg/L.
4. Design temperature is 30oC.
Design Considerations
1. Rock media trickling filters is used for high rate trickling filters (Liu and Liptak.
1999. Environmental Engineer’s Handbook. 2nd Edition. Section 7.23).
1. The Hydraulic Loading for rock media trickling filters is 0.16 – 0.64 gal/ft2-min
(Liu and Liptak. 1999. Environmental Engineer’s Handbook. 2nd Edition.
Section 7.23).
2. The BOD Removal Efficiency of 90% is feasible on rock media trickling filter (Liu
and Liptak. 1999. Environmental Engineer’s Handbook. 2nd Edition. Section
7.23).
3. A depth of 8 ft is used (Liu and Liptak. 1999. Environmental Engineer’s
Handbook. 2nd Edition. Section 7.23).
4. For rock media trickling filters at high rate has a recirculation ratio, r of 1 (Liu
and Liptak. 1999. Environmental Engineer’s Handbook. 2nd Edition. Section
7.23).
5. The treatability constant, ko for a 12-m rock media trickling filter is 0.036/min
(Liu and Liptak. 1999. Environmental Engineer’s Handbook. 2nd Edition.
Section 7.23.3).
6. The n factor is 0.67 for rock media (Liu and Liptak. 1999. Environmental
Engineer’s Handbook. 2nd Edition. Figure 7.23.4).
7. A minimum clearance of 6 inches between the media and distributor arm is
required (Guyer, J.P. An Introduction to Trickling Filter Wastewater Treatment
Plants. p. 12).

8. The Spulkraft flushing intensity (SK) recommendations for rock filters were 2 to
6mm/pass of arm (Albertson, O.E. Slow Down That Trickling Filter!).
Design Requirements
1. Capacity
2. Treatability Constant
3. Surface Area
4. Hydraulic Loading Rate
5. Organic Loading Rate
6. Residence Time
7. Rotational Speed of Distributor Arms
8. Mass of BOD Removed
9. Mass and Volume of Effluent
10. Power Requirements
Design Calculation
1. Peak Flow Rate, Q
If there are no data for peak flow rates available, then (Guyer, J.P. An
Introduction to Trickling Filter Wastewater Treatment Plants):
Q = 3 x influent flow
Q = 3 x 81.06 m3/day
Q = 243.18 m3/day
Use: Q = 243.18 m3/day
2. Treatability Constant, k
To correct treatability constant for a certain depth (Liu and Liptak. 1999.
Environmental Engineer’s Handbook. 2nd Edition.):
𝐷 𝑛
𝑘 = 𝑘𝑜 ( )
𝐷𝑂
Where: k = treatability constant corresponding to filter depth D
ko = treatability constant corresponding to filter depth Do
0.036 8 0.67
𝑘= x( ) = 0.0274/𝑚𝑖𝑛
min 12 𝑚

Use: k = 0.0274/min
3. Surface Area
Using Veltz Equation (Liu and Liptak. 1999. Environmental Engineer’s
Handbook. 2nd Edition. Eqn. 7.23-1):
𝑛
𝑆𝑖 + 𝑟𝑆𝑒 −𝑘𝐷𝐴𝑛 (1.035𝑇−20 )
𝑆𝑒 = 𝑒 𝑄
1+𝑟
Where:
Se = effluent BOD from filter, mg/L =
Si = influent BOD from filter, mg/L =
r = ratio of recirculated flow to wastewater flow =1
D = filter depth, m = 8 ft = 2.4384 m
A = surface area, m2 =to be determined
Q = wastewater flow, m3/min = 243.18 m3/day = 0.1689 m3/min
T = wastewater temperature, oC = 30
k = treatability constant, min-1 = 0.0274/min
𝑚𝑔
118.93
𝐿
𝑚𝑔 𝑚𝑔
1189.3 𝐿 + 118.93 𝐿 −0.0274/ min x 2.4384 m x 𝐴0.67
(1.03530−20 )
= 𝑥𝑒 0.16890.67
1+1
A = 12.7159 m2
d = 4.02 m
Use: A = 13 m2; d = 4.1 m
4. Hydraulic Loading Rate
It is the flow of wastewater applied to the trickling filter per unit of surface area,
calculated by:
𝑄
𝐻𝐿𝑅 =
𝐴
m3
243.18
day
𝐻𝐿𝑅 = = 18.7062 𝑚3 /𝑑𝑎𝑦/𝑚2
13 𝑚2
Use: HLR =18.8 𝒎𝟑 /𝒅𝒂𝒚/𝒎𝟐
5. Organic Loading Rate
It is defined as the pounds of Biochemical Oxygen Demand applied to the trickling
filter per 1,000 ft3 of volume of media per day, calculated by:
𝑂𝐿𝑅, 𝑙𝑏 𝐵𝑂𝐷/𝑑𝑎𝑦/1000 𝑓𝑡 3
𝑚𝑔 𝑙𝑏
𝐵𝑂𝐷, 𝐿 𝑥 𝑓𝑙𝑜𝑤, 𝑚𝑔𝑑 𝑥 8.34 𝑥 1000 𝑓𝑡 3
𝑔𝑎𝑙𝑙𝑜𝑛
=
𝑀𝑒𝑑𝑖𝑎 𝑉𝑜𝑙𝑢𝑚𝑒, 𝑓𝑡 3

𝑂𝐿𝑅, 𝑙𝑏 𝐵𝑂𝐷/𝑑𝑎𝑦/1000 𝑓𝑡 3
𝑚𝑔 𝑙𝑏
1189.3 𝐿 𝑥 0.0214 𝑚𝑔𝑑 𝑥 8.34 𝑥 1000 𝑓𝑡 3
𝑔𝑎𝑙𝑙𝑜𝑛
=
1119.45 𝑓𝑡 3
𝑂𝐿𝑅, 𝑙𝑏 𝐵𝑂𝐷/𝑑𝑎𝑦/1000 𝑓𝑡 3 = 189.6123
Use: OLR = 189.7
6. Residence Time
To calculate for residence time (Liu and Liptak. 1999. Environmental
Engineer’s Handbook. 2nd Edition. SectionFigure 7.23.4):
𝐷, 𝑓𝑡
𝑡, 𝑚𝑖𝑛 = 0.5 𝑛
𝑄, 𝑔𝑝𝑚. 𝑓𝑡 2
8
𝑡, 𝑚𝑖𝑛 = 0.5 𝑥 = 8.6040 𝑚𝑖𝑛
0.31880.67
For an area of 139.9 ft2
Use: t = 20.1 hours
7. Rotational Speed of Distributor Arms
Using the equation for Spulkraft flushing intensity (SK) calculation:
𝐻𝐿𝑅, 𝑚3 / 𝑚2 /ℎ 𝑥1000𝑚𝑚/𝑚
𝑆𝐾, 𝑚𝑚/𝑝𝑎𝑠𝑠 =
𝑎 𝑥 𝑛, 𝑟𝑝𝑚 𝑥 60 𝑚𝑖𝑛/ℎ𝑟
Where: a = number of arms = 2
n = rotational speed
0.7833 𝑚3 / 𝑚2 /ℎ 𝑥1000𝑚𝑚/𝑚
6 𝑚𝑚/𝑝𝑎𝑠𝑠 =
2 𝑥 𝑛, 𝑟𝑝𝑚 𝑥 60 𝑚𝑖𝑛/ℎ𝑟
n= 1.1
Use: n= 1.1 rpm
8. Mass of BOD Removed
𝑀𝐵𝑂𝐷𝑟𝑒𝑚𝑜𝑣𝑒𝑑 = (𝑆𝑖 − 𝑆𝑒 )(𝑖𝑛𝑓𝑙𝑢𝑒𝑛𝑡 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒)
𝑚𝑔 1000 𝐿 𝑘𝑔 103,328.27 𝑘𝑔
𝑀𝐵𝑂𝐷𝑟𝑒𝑚𝑜𝑣𝑒𝑑 = (1189.3 − 118.93) 𝑥 𝑥 𝑥 ( )
𝐿 𝑚 3 6
10 𝑚𝑔 𝑘𝑔
1274.78 3
𝑚
= 86.7597 𝑘𝑔
𝑴𝑩𝑶𝑫𝒓𝒆𝒎𝒐𝒗𝒆𝒅 = 𝟖𝟔. 𝟕𝟔 𝒌𝒈
9. Mass and Volume of Effluent
𝑀𝑒𝑓𝑓 = 𝑖𝑛𝑓𝑙𝑢𝑒𝑛𝑡 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 − 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐵𝑂𝐷𝑟𝑒𝑚𝑜𝑣𝑒𝑑
𝑒𝑓𝑓𝑙𝑢𝑒𝑛𝑡 = 103,328.27 𝑘𝑔 – 86.76 𝑘𝑔 = 103,241.51 𝑘𝑔
𝑬𝒇𝒇𝒍𝒖𝒆𝒏𝒕 = 𝟏𝟎𝟑, 𝟐𝟒𝟏. 𝟓𝟏 𝒌𝒈
𝑼𝒔𝒆: 𝑽𝒆𝒇𝒇 = 𝟖𝟏. 𝟎 𝒎𝟑
10. Power Requirement

For high rate rock media trickling filters, 6 kW/103 m3 is consumed, thus:
6 kW
𝑃 = 𝟐𝟒𝟑. 𝟏𝟖 𝐦𝟑 𝑤𝑎𝑠𝑡𝑒𝑤𝑎𝑡𝑒𝑟 𝑥 = 1.4591 𝑘𝑊 = 1.9566 ℎ𝑃
1000 𝑚3
Use: P = 2 hP
Design Specifications
TRICKLING FILTER
OPERATING DATA
Number of Units 1
Feed Effluent from UASB
Function To reduce BOD from 1189.3 mg/L to 118.93 mg/L
TECHNICAL DATA
Surface Area 13 m3 Minimum 0.10 m2
Hydraulic Loading 18.8 m3/day/m2 Minimum 0.5 m3/day/m2
189.7 lb BOD/day/1000
Organic Loading -
ft3
Rotational Speed of
1.1 rpm -
Distributor Arm
Number of Distributor
2 2-4
Arm
Residence Time 20.1 hours 3hrs - 1 day
Power Requirement 2 hP -
EFFLUENT DATA
Mass 103,241.51 kg
BOD 118.93 mg/L
TSS 279.3 mg/L
COD 220.88 mg/L
Company Name Brentwood Industries Inc.
Company Address Myron L Company, Philippines (Distributor)
Cost Php 601,842.21
Expected Useful Life 30 years

DESIGN CONFIGURATION OF TRICKLING FILTER

AERATED LAGOON
Factors to Consider in Designing an Activated Sludge Process
In the design of the activated sludge process, consideration must be given to:
1. Selection of the reactor type
2. Applicable kinetic relationships
3. Solids retention time and loading criteria to be used
4. Sludge production
5. Oxygen requirements and transfer
6. Nutrient requirements
7. Other chemical requirements
8. Settling characteristics of bio-solids
9. Use of selectors
10. Effluent characteristics
In line with this, a physical facility used in the design of activated-sludge

treatment systems is an aerated lagoon (Wastewater Engineering: Treatment and
Reuse, 4th Ed. by Tchobanoglous, et. al., Metcalf & Eddy, Inc.).
Step-by-Step Procedure in Designing an Aerated Lagoon
1. Establish influent wastewater characteristics and effluent requirements –
BOD, COD, and TSS.
2. Compute the influent wastewater flowrate per day. This will be used in the
surface area calculation.
3. Calculate the capacity of the lagoon using the influent volumetric flowrate (per
day) and the detention time. Apply the safety factor. This will be used in the
calculation of dimensions.
4. Solve for the surface area of the lagoon using the influent volumetric flowrate
(per day) and the surface loading rate for the dimensions calculation.
5. Calculate the height of the lagoon by using the volume and the surface area of
the lagoon. Solve for the length and the width.
6. Compute the kg per wk solids removed. This will be used in the calculation of
the volumetric flowrate of the effluent and the power requirement.

7. Solve for the volumetric flowrate of the effluent. This shall be used in the
computation of the oxygen requirement.
8. Compute for the oxygen requirement and the needed kg of air per day. This will
be used for the power requirement calculation.
9. Calculate the power requirement.
Actual Design of an Aerated Lagoon

Design Problem
103,241.51 kg of wastewater per 6 days of operation from the production
process of tylose powder enters per batch and is to be treated in an aerated lagoon.
Design an aerated lagoon that will bring the BOD, COD and TSS of the wastewater
from 118.93 mg/L to 17.84 mg/L, 220.88 mg/L to 44.18 mg/L, and 279.30 mg/L
to 55.86 mg/L, respectively.
Design Description
An aerated lagoon is a simple wastewater treatment system that is used to
reduce the organic matter content of wastewater through aerated activity of
microorganisms which convert it to cell tissues or gases. A typical open aerated
lagoon consists of a relatively shallow earthen or concrete basins varying in depth
from 2 – 5 m with artificial aeration to promote the biological oxidation of
wastewaters (Wastewater Engineering: Treatment and Reuse, 4th Ed. by
Tchobanoglous, et. al., Metcalf & Eddy, Inc., p.840).
The aerated lagoon operates on the principle of aerated suspended-growth
biological process. The wastewater which contains organic matter is fed to the
aerated lagoon under controlled flow conditions. The microbial activity of the
activated sludge (flocs of active bacteria which consume and remove aerobically
biodegradable organic substances) is enhanced by aerating the wastewater. This
promotes the dissolution of oxygen into the wastewater which is needed for the
respiration and digestion mechanism of microorganisms. The organic matter is
converted either into cell tissues of another microorganism or to gases.
Design Selection
Aerated lagoon was chosen because of its aerated suspended-growth
process. It is a rapid and the most efficient wastewater biological treatment process
which removes up to 98% of organic contaminants. Aeration causes effective
breakdown of organic pollutants and yields a cleaner water effluent than anaerobic
treatment. There is also no medium needed which makes the maintenance of
equipment easier as compared to aerated attached-growth process.

Parts and its Functions
1 – Inlet Pipe
2 – Baffle Wall
3 – Water Level
4 – Outlet Launder
5 – Net or Screen
6 – Outlet Pipe
7 – Bubble Diffusers
8 – Header Pipe
9 – Recirculated Sludge Pipeline
Parts of an Aerated Lagoon
Parts Functions
Inlet Pipe The inlet pipe brings the black liquor wastewater to aeration
tank.
Baffle Wall The baffle wall does not let the incoming wastewater go across
the tank toward the outlet pipe. The wall forces the mix toward
the bottom of the tank and thus ensuring maximum retention.
Outlet Launder The outlet launder collects the wastewater and delivers it to
the outlet pipe. It should be located farthest from the inlet
pipe
Net or Screen The net or screen prevents entry of debris in the outlet pipe.
Outlet Pipe The outlet pipe takes the wastewater to the final clarifier.
Bubble Diffusers The bubble diffusers are rigid pipes with long slots, which are
covered with rubber membranes. The compressed air is
released throughout the length of the diffusers, through
minute holes punched in the rubber membrane.
Header Pipe The header pipe supplies the compressed air in the diffusers.
Recirculated The recirculated sludge pipeline brings bacteria floc back to
Sludge Pipeline the aeration tank. It is always located very close to the inlet so
that the raw wastewater and bacteria get mixed thoroughly.
Design Assumptions
1. The wastewater from trickling filter is 103,241.51 kg.
2. The BOD of the influent wastewater is 118.93 ppm.

3. The COD of the influent wastewater is 220.88 ppm.

4. The total suspended solid of the influent wastewater is 279.30 ppm.
5. The density of the influent at 30°C is 1274.78 kg/m3.
6. The volumetric flowrate of influent is 80.9877 m3
Design Considerations
1. A safety factor of 20% is typically used in designing aerated lagoons (Plant
Design and Economics for Chemical Engineers, 4th Edition by Peters and
Timmerhaus, Table 6, p. 37).
2. The lagoon has a rectangular shape and is constructed using a concrete
material (Introduction to Wastewater Treatment Processes by Ramallho, p.
160).
3. The typical efficiency of the aerated lagoon for the removal of Biochemical
Oxygen Demand is 85% (Wastewater Engineering: Treatment and Reuse, 4th
Ed. by Tchobanoglous, et. al., Metcalf & Eddy, Inc.).
4. The typical efficiency of the aerated lagoon for the removal of Chemical Oxygen
Demand is 80% (Wastewater Engineering: Treatment and Reuse, 4th Ed. by
Tchobanoglous, et. al., Metcalf & Eddy, Inc.).
5. The typical efficiency of the aerated lagoon for the removal of Total Suspended
Solids is 80% (Wastewater Engineering: Treatment and Reuse, 4th Ed. by
Tchobanoglous, et. al., Metcalf & Eddy, Inc.).
6. The typical surface loading rate ranges from 4 to 10 m3/m2-d. A surface loading
rate of 4 m3/m2-d is applied in the design (Introduction to Wastewater
Treatment Processes by Ramalho, p. 161).
7. The width to length ratio for tank may range from 1:1 to 2.2:1, with 1.5:1 being
the most common. In this design, 1.5:1 will be used for the calculation.
(Wastewater Engineering: Treatment and Reuse, 4th Ed. by Tchobanoglous, et.
al., Metcalf & Eddy, Inc., p. 817).

8. The typical removal rate constant k for an activated-sludge system of an

industrial wastewater is 0.0161 which corresponds to Sn being equal to 10
mg/L. (Introduction to Wastewater Treatment Processes, R.S. Ramalho, p 212)
9. The typical value for a’ and b’ for the calculation of oxygen requirement is 0.79
and 1.15 lb O2/lb BODr per day (Introduction to Wastewater Treatment
Processes, R.S. Ramalho, p. 202).
Design Requirements
1. Characteristics of Effluent
a. BOD
b. COD
c. TSS
2. Volumetric Flowrate of Effluent
3. Detention Time
4. Capacity
5. Surface Area
6. Activated Sludge Reactor Dimensions
7. Oxygen Requirement
Design Calculations
1. Characteristics of Effluent
The characteristics of the effluent are determined by the efficiency of removal.
a. BOD 𝐵𝑂𝐷𝐸𝑓𝑓𝑙𝑢𝑒𝑛𝑡 = 𝐵𝑂𝐷𝐼𝑛𝑙𝑢𝑒𝑛𝑡 (1 − 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦)
𝐵𝑂𝐷𝐸𝑓𝑓𝑙𝑢𝑒𝑛𝑡 = (118.93 𝑝𝑝𝑚)(1 − 0.85)
𝑩𝑶𝑫𝑬𝒇𝒇𝒍𝒖𝒆𝒏𝒕 = 𝟏𝟕. 𝟖𝟒 𝒑𝒑𝒎
b. COD 𝐶𝑂𝐷𝐸𝑓𝑓𝑙𝑢𝑒𝑛𝑡 = 𝐶𝑂𝐷𝐼𝑛𝑙𝑢𝑒𝑛𝑡 (1 − 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦)
𝐶𝑂𝐷𝐸𝑓𝑓𝑙𝑢𝑒𝑛𝑡 = (220.88 𝑝𝑝𝑚)(1 − 0.80)
𝑪𝑶𝑫𝑬𝒇𝒇𝒍𝒖𝒆𝒏𝒕 = 𝟒𝟒. 𝟏𝟖 𝒑𝒑𝒎
c. TSS 𝑇𝑆𝑆𝐸𝑓𝑓𝑙𝑢𝑒𝑛𝑡 = 𝑇𝑆𝑆𝐼𝑛𝑙𝑢𝑒𝑛𝑡 (1 − 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦)

𝑇𝑆𝑆𝐸𝑓𝑓𝑙𝑢𝑒𝑛𝑡 = (279.30 𝑝𝑝𝑚)(1 − 0.80)

𝑻𝑺𝑺𝑬𝒇𝒇𝒍𝒖𝒆𝒏𝒕 = 𝟓𝟓. 𝟖𝟔 𝒑𝒑𝒎
2. Volumetric Flowrate of Effluent

𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐹𝑙𝑜𝑤𝑟𝑎𝑡𝑒𝑒𝑓𝑓𝑙𝑢𝑒𝑛𝑡
= 𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐹𝑙𝑜𝑤𝑟𝑎𝑡𝑒𝑖𝑛𝑓𝑙𝑢𝑒𝑛𝑡
𝑘𝑔 𝑚3 1 𝑚3
− (𝑆𝑜𝑙𝑖𝑑𝑠 𝑟𝑒𝑚𝑜𝑣𝑒𝑑, 3 ) (𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐹𝑙𝑜𝑤𝑟𝑎𝑡𝑒𝑖𝑛𝑓𝑙𝑢𝑒𝑛𝑡 , )( , )
𝑚 𝑏𝑎𝑡𝑐ℎ 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑘𝑔
𝑚𝑔 1𝑘𝑔 1000𝐿
𝑆𝑜𝑙𝑖𝑑𝑠 𝑅𝑒𝑚𝑜𝑣𝑒𝑑 = (∆𝐵𝑂𝐷 + ∆𝐶𝑂𝐷 + ∆𝑇𝑆𝑆, )( ) ( )
𝐿 1 × 106 𝑚𝑔 1𝑚3
1𝑘𝑔 1000𝐿
𝑆𝑜𝑙𝑖𝑑𝑠 𝑅𝑒𝑚𝑜𝑣𝑒𝑑 = (101.09 + 176.70 + 223.44 𝑝𝑝𝑚) ( 6
)( )
1 × 10 𝑚𝑔 1𝑚3
𝒌𝒈
𝑺𝒐𝒍𝒊𝒅𝒔 𝑹𝒆𝒎𝒐𝒗𝒆𝒅 = 𝟎. 𝟓𝟎𝟏𝟐 (𝟖𝟎. 𝟗𝟖𝟕𝟕 𝒎𝟑 )
𝒎𝟑
𝑺𝒐𝒍𝒊𝒅𝒔 𝑹𝒆𝒎𝒐𝒗𝒆𝒅 = 𝟒𝟎. 𝟓𝟗 𝒌𝒈
𝑚3
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐹𝑙𝑜𝑤𝑟𝑎𝑡𝑒𝑒𝑓𝑓𝑙𝑢𝑒𝑛𝑡 ,
𝑤𝑘
𝑚3
= 𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐹𝑙𝑜𝑤𝑟𝑎𝑡𝑒𝑖𝑛𝑓𝑙𝑢𝑒𝑛𝑡 ,
𝑤𝑘
𝑘𝑔 𝑚3 1 𝑚3
− (𝑆𝑜𝑙𝑖𝑑𝑠 𝑟𝑒𝑚𝑜𝑣𝑒𝑑, 3 ) (𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐹𝑙𝑜𝑤𝑟𝑎𝑡𝑒𝑖𝑛𝑓𝑙𝑢𝑒𝑛𝑡 , ) ( , )
𝑚 𝑤𝑘 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑘𝑔
𝑚3
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐹𝑙𝑜𝑤𝑟𝑎𝑡𝑒𝑒𝑓𝑓𝑙𝑢𝑒𝑛𝑡 ,
𝑤𝑘
𝑚3 0.5012 𝑘𝑔 1 𝑚3 𝑚3
= 80.9877 −( ) ( ) (80.9877 )
𝑤𝑘 𝑚3 1274.78 𝑘𝑔 𝑤𝑘
𝒎𝟑 𝒎𝟑
𝑽𝒐𝒍𝒖𝒎𝒆𝒕𝒓𝒊𝒄 𝑭𝒍𝒐𝒘𝒓𝒂𝒕𝒆𝒆𝒇𝒇𝒍𝒖𝒆𝒏𝒕 , = 𝟖𝟎. 𝟗𝟓𝟓𝟗
𝒅 𝒅
Accounting for 20% safety factor and 80% filling capacity:
𝑚3 𝑚3 1.20 1 𝑤𝑘
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐹𝑙𝑜𝑤𝑟𝑎𝑡𝑒𝑒𝑓𝑓𝑙𝑢𝑒𝑛𝑡 , = 80.9559 ( )×
𝑤𝑘 𝑤𝑘 0.80 7𝑑
𝒎𝟑 𝒎𝟑
𝑽𝒐𝒍𝒖𝒎𝒆𝒕𝒓𝒊𝒄 𝑭𝒍𝒐𝒘𝒓𝒂𝒕𝒆𝒆𝒇𝒇𝒍𝒖𝒆𝒏𝒕 , = 𝟏𝟕. 𝟑𝟓
𝒅 𝒅
3. Detention Time
𝐵𝑂𝐷𝑖𝑛𝑓𝑙𝑢𝑒𝑛𝑡 − 𝐵𝑂𝐷𝑒𝑓𝑓𝑙𝑢𝑒𝑛𝑡
𝑡=
𝑘(𝑇𝑆𝑆𝑖𝑛𝑓𝑙𝑢𝑒𝑛𝑡 + 𝐶𝑂𝐷𝑖𝑛𝑓𝑙𝑢𝑒𝑛𝑡 + 𝐵𝑂𝐷𝑖𝑛𝑓𝑙𝑢𝑒𝑛𝑡 )(𝐵𝑂𝐷𝑒𝑓𝑓𝑙𝑢𝑒𝑛𝑡 − 𝑆𝑛 )

(118.93 − 17.84) 𝑝𝑝𝑚

𝑡=
0.0161
(279.30 + 220.88 + 118.93 𝑝𝑝𝑚)(17.84 − 10 𝑝𝑝𝑚)
𝑝𝑝𝑚 − 𝑑𝑎𝑦
𝒕 = 𝟏. 𝟐𝟗 𝒅𝒂𝒚𝒔 = 𝟑𝟎. 𝟗𝟔 𝒉𝒐𝒖𝒓𝒔
4. Capacity
The capacity of the lagoon can be calculated using the volumetric flow rate per
day and the detention time.
𝑉𝑎𝑐𝑡𝑖𝑣𝑎𝑡𝑒𝑑−𝑠𝑙𝑢𝑑𝑔𝑒 𝑟𝑒𝑎𝑐𝑡𝑜𝑟 = 𝑉𝑖𝑛𝑓𝑙𝑢𝑒𝑛𝑡 × 𝑑𝑒𝑡𝑒𝑛𝑡𝑖𝑜𝑛 𝑡𝑖𝑚𝑒
𝑚3 1 𝑤𝑘
𝑉𝑎𝑐𝑡𝑖𝑣𝑎𝑡𝑒𝑑−𝑠𝑙𝑢𝑑𝑔𝑒 𝑟𝑒𝑎𝑐𝑡𝑜𝑟 = 80.9877 × 1.29 𝑑 ×
𝑤𝑘 7𝑑
𝑽𝒂𝒄𝒕𝒊𝒗𝒂𝒕𝒆𝒅−𝒔𝒍𝒖𝒅𝒈𝒆 𝒓𝒆𝒂𝒄𝒕𝒐𝒓 = 𝟏𝟒. 𝟗𝟐 𝒎𝟑
5. Surface Area
The surface area of the activated-sludge reactor can be calculated using the
volumetric flow rate of the influent and the surface loading rate.
𝑚3
17.35
𝐴= 𝑑
𝑚3
4
𝑚2 − 𝑑
𝑨 = 𝟒. 𝟑𝟒𝒎𝟐
6. Activated-Sludge Reactor Dimensions
The height can be computed by dividing the volume by the surface area.
𝑉𝑠𝑒𝑡𝑡𝑙𝑖𝑛𝑔 𝑏𝑎𝑠𝑖𝑛
𝐻=
𝐴
14.92 𝑚3
𝐻= = 𝟑. 𝟒𝟒 𝒎
4.34 𝑚2
USE 𝑯 = 𝟑. 𝟓 𝒎
Any practical combination of width and length can be used to satisfy the surface
area requirement. For the purpose of the design, it is assumed that the length
to width ratio is 1:1.5 as it is the most common L/W ratio being used in the
industry. Thus, the reactor dimension is:
𝑆𝑢𝑟𝑓𝑎𝑐𝑒 𝐴𝑟𝑒𝑎 = 𝐿 × 𝑊
𝐿 = 1.5𝑊
4.34 𝑚2 = (1.5𝑊)(𝑊)
𝑊 = 1.70 𝑚

𝐿 = 2.55 𝑚
USE 𝑾 = 𝟏. 𝟕𝟎 𝒎
𝑳 = 𝟐. 𝟔𝟎 𝒎
7. Oxygen Requirement
The oxygen utilization of the activated-sludge system is based on total of the
oxygen required for energy or for oxidation and oxygen required for endogenous
respiration.
𝑇𝑜𝑡𝑎𝑙 𝑂𝑥𝑦𝑔𝑒𝑛 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑
= 𝑂𝑥𝑦𝑔𝑒𝑛 𝑓𝑜𝑟 𝐸𝑛𝑒𝑟𝑔𝑦 + 𝑂𝑥𝑦𝑔𝑒𝑛 𝑓𝑜𝑟 𝐸𝑛𝑑𝑜𝑔𝑒𝑛𝑜𝑢𝑠 𝑅𝑒𝑠𝑝𝑖𝑟𝑎𝑡𝑖𝑜𝑛
𝑇𝑜𝑡𝑎𝑙 𝑂𝑥𝑦𝑔𝑒𝑛 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = 𝑎′ (∆𝐵𝑂𝐷)𝑄 + 𝑏 ′ (𝑇𝑆𝑆𝑖𝑛𝑓𝑙𝑢𝑒𝑛𝑡 )𝑉
𝑇𝑜𝑡𝑎𝑙 𝑂𝑥𝑦𝑔𝑒𝑛 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑
𝑙𝑏 𝑂2 𝑚𝑔
= [0.79 (118.93 − 17.84 )
𝑙𝑏 𝐵𝑂𝐷𝑟 𝐿
8.34 𝑙𝑏 𝐵𝑂𝐷𝑟 𝑚3 1 𝑀𝑔𝑎𝑙

×( 𝑚𝑔 ) (17.35 𝑑 ) (3785.412 𝑚3 )]
𝑀𝑔𝑎𝑙 − 𝐿
1.15 𝑙𝑏 𝑂2 𝑚𝑔 8.34 𝑙𝑏 𝐵𝑂𝐷𝑟 3)

1 𝑀𝑔𝑎𝑙
+[ (279.30 )( 𝑚𝑔 ) (14.92 𝑚 ( )]
𝑙𝑏 𝐵𝑂𝐷𝑟 − 𝑑 𝐿 𝑀𝑔𝑎𝑙 − 𝐿 3785.412 𝑚3
𝑙𝑏 𝑂2 𝑙𝑏 𝑂2 𝒍𝒃 𝑶𝟐
𝑇𝑜𝑡𝑎𝑙 𝑂𝑥𝑦𝑔𝑒𝑛 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = 3.0527 + 10.5582 = 𝟏𝟑. 𝟔𝟏𝟎𝟗
𝑑 𝑑 𝒅𝒂𝒚
𝒌𝒈 𝑶𝟐
= 𝟔. 𝟏𝟕𝟐𝟕
𝒅𝒂𝒚
100
𝑇𝑜𝑡𝑎𝑙 𝐴𝑖𝑟 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = 6.1727 ( )
21
𝒌𝒈 𝑨𝒊𝒓
𝑻𝒐𝒕𝒂𝒍 𝑨𝒊𝒓 𝑹𝒆𝒒𝒖𝒊𝒓𝒆𝒅 = 𝟐𝟗. 𝟑𝟗
𝒅𝒂𝒚
The power requirement of the blowers that will supply the air to the diffusers can
be calculated using the equation provided in Wastewater Engineering, Treatment
and Reuse, Metcalf/Eddy. 3rd Ed, p. 565:
𝑤𝑅𝑇 𝑃2 0.283
𝑃= [( ) − 1]
550 𝑛𝑒 𝑃1
Where P is the power is hP
W is the weight of flow of air in lb/s
R is the gas constant for air equivalent to 53.3 ft*lb/lb air*R

T is the temperature in R
P1 is the absolute inlet pressure in psi
P2 is the absolute outlet pressure in psi
n = 0.0283 for air
e is efficiency, (usual range for compressor is 0.7 to 0.9)
𝑘𝑔 2.205 𝑙𝑏 1𝑑 𝑓𝑡 ∗ 𝑙𝑏
(29.39 )( ) (86,400 𝑠) (53.3 )(546 𝑅) 30.0 𝑝𝑠𝑖 0.283
𝑑 1 𝑘𝑔 𝑙𝑏 𝑎𝑖𝑟 ∗ 𝑅
𝑃= [( )
550 (0.0283)(0.80) 14.7 𝑝𝑠𝑖
− 1] = 0.3921ℎ𝑃
The total power requirement for the blower is 0.5 hP.
Design Specification
AERATED LAGOON SPECIFICATION SHEET
OPERATING DATA
Mode of Operation Continuous
Number of Units 1
To reduce BOD, COD and TSS prior to discharge to
Function
receiving body
Compound Raw Influent Treated Effluent
Volume
81.00 80.96
(m3/wk)
Feed
BOD (mg/L) 118.93 17.84
COD (mg/L) 220.88 44.18
TSS (mg/L) 279.30 55.86
TECHNICAL DATA
Detention Time 30.96 hours
Capacity 17.35 cu. m.
Surface Area 4.34 sq. m.
Height 3.50 m
Length 2.60 m
Width 1.70 m
Surface Loading Rate 4 m3/m2-d
Air Requirement 29.39 kg Air/d
Power Requirement 0.50 hP
Materials of Construction Concrete
EFFLUENT DATA
Flowrate 17.45 m3/d

BOD 17.84 mg/L

TSS 55.86 mg/L
COD 44.18 mg/L
EXISTING EQUIPMENT
Supplier Energreen Technology Inc.
Supplier Address Ortigas Center, Pasig Philippines

Cost Php 399,280 ($8,000)
Expected Useful Life 15 years
DESIGN CONFIGURATION AERATED LAGOON
Width = 1.7 m
Height = 3.5 m
Length = 2.6 m
Air Diffusers
Capacity = 17.35 m3
Concrete Tank

PIPING
Introduction
Piping systems are like arteries and veins as

they carry the lifeblood of modern civilization. In a
modern city, they transport water from the sources
of water supply to the points of distribution; convey
waste from residential and commercial buildings
and other civic facilities to the treatment facility or
the point of discharge. Similarly, pipelines carry
crude oil from oil wells to tank farms for storage or to refineries for processing. The
natural gas transportation and distribution lines convey natural gas from the source
and storage tank forms to points of utilization, such as power plants, industrial
facilities, and commercial and residential communities. In chemical plants, paper
mills, food processing plants, and other similar industrial establishments, the piping
systems are utilized to carry liquids, chemicals, mixtures, gases, vapors, and solids
from one location to another.
The fire protection piping networks in residential, commercial, industrial, and

other buildings carry fire suppression fluids, such as water, gases, and chemicals to
provide protection of life and property. The piping systems in thermal power plants
convey high-pressure and high-temperature steam to generate electricity. Other piping
systems in a power plant transport high- and low-pressure water, chemicals, low-
pressure steam, and condensate. Sophisticated piping systems are used to process
and carry hazardous and toxic substances. The storm and wastewater piping systems
transport large quantities of water away from towns, cities, and industrial and similar
establishments to safeguard life, property, and essential facilities.
The design, construction, operation, and maintenance of various piping

systems involve understanding of piping fundamentals, materials, generic and specific

design considerations, fabrication and installation, examinations, and testing and

inspection requirements, in addition to the local, state and federal regulations.
Piping includes pipe, flanges, fittings, bolting, gaskets, valves, and the pressure
containing portions of other piping components. It also includes pipe hangers and
supports and other items necessary to prevent overpressurization and overstressing
of the pressure-containing components. It is evident that pipe is one element or a part
of piping. Therefore, pipe sections when joined with fittings, valves, and other
mechanical equipment and properly supported by hangers and supports, are called
piping.
Color Coding of Pipeline and Piping Identification
Oil and gas industries and other process industries are complex installation.
Piping systems are used in these plants to transport various fluids. These pipelines
transport various industrial materials such as gases such as air, nitrogen, oxygen,
hydrogen etc., liquids such as water, acids, hydrocarbon, toxic materials etc.
Without proper pipe color code, it is extremely difficult to identify the material
pipeline transporting. To reduces the safety hazard, reduce the possibility of mistakes
in identification and accidents associated with wrong identification of pipeline during
the emergency situation, systematic color coding of pipeline and piping system is
essential. Uniformity of color marking promotes greater safety, lessens the chances of
error and reduces hazards involved in the handling of material inside the pipelines.
One of the standards used for uniform color coding in industries is the ASME
A13.1 – Scheme for the Identification of Piping Systems. The purpose of ASME/ANSI
A13.1 Standard is to establish a common system that assists in the identification of
hazardous materials conveyed in piping systems and their hazards when released into
the environment.

ASME A13.1 – 2015 edition has six fixed colors and 4 users define colors that
can be used to identify the hazardous material. In this standard, following category are
used:
1) Flammable – fluids or a vapor or produce vapors that can be ignited and
continue to burn in air.
2) Combustible – fluids that can burn, but are not flammable.
3) Oxidizing – oxidizing fluid is any gas or liquid that may, generally by providing
oxygen, cause or contribute to the combustion of other material more than air
does.
4) Toxic and Corrosive – fluids that are corrosive or toxic, or will produce corrosive
or toxic substances when released.
5) Fire Quenching – fluid Such as water, foam, and CO2 used in sprinkler systems
and firefighting piping systems.

Codes and Standards
Units: Pipe and Tubing Sizes and Ratings

Pipe and tubing sizes are generally quoted in units of inches. To convert inches
to millimeters, multiply by 25.4. Ratings are given in pounds. To convert pounds to
kilograms, multiply by 0.454.
Pressure-Piping Codes
The code for pressure piping (ASME B31) consists of a number of sections
which collectively constitute the code. Table 10-18 of Perry's Chemical Engineers'
Handbook shows the status of the B31 code as of July 2005. The sections are
published as separate documents for simplicity and convenience. The sections differ
extensively. The ASME B31 code prescribes minimum requirements for materials,
design, fabrication, assembly, support, erection, examination, inspection, and testing
of piping systems subject to pressure or vacuum. The scope of the piping covered by
B31.3 is illustrated in Fig. 10-127.
The code also excludes piping systems designed for internal gauge pressures
at or above zero but less than 0.105 MPa (15 lbf/in2) provided the fluid handled is
nonflammable, nontoxic, and not damaging to human tissues, and its design
temperature is from −29°C (−20°F) through 186°C (366°F). Refer to the code for
definitions of nonflammable and nontoxic.
Some of the more significant requirements of ASME B31.3 (2004 edition) have
been summarized and incorporated in this section of the Handbook. For a more

comprehensive treatment of code requirements engineers are referred to the B31.3

code and the standards referenced therein.
International Regulations
ASME piping codes have been widely used throughout the world for the design
of facilities falling within their defined scopes. Although the use of ASME codes is
widely acceptable in areas outside the United States, it is essential to identify
additional local or national codes or standards that may apply. Such documents may
require qualified third-party review and approval of project specifications, facility
design, fabrication, material documentation, inspection, and testing. For example,
within the European Community, such requirements are imposed by the Pressure
Equipment Directive 97/23/EC (also known as the PED). These requirements must be
recognized early in the project to avoid costly error.
Components of Piping System

The piping system consists of three (3) major components such as the pipe,
valves and fittings.
A. Pipes
A.1 Classification of Pipes
Pipes are divided into two main categories: seamless and welded. Both have
advantages and disadvantages in terms of economy and function. Specifications
governing the production of these products dictate the permissible mechanical and
dimensional variations, and code design calculations account for these variations.
❖ Seamless Pipe
Seamless pipe may be formed by
various methods. A common technique involves
piercing solid round forgings, followed by rolling
and drawing. Since seamless products have no

weld joints, there is no reduction of strength due to weld joint efficiency. Standard
seamless pipes are more commonly used than welded pipes and they tend to be
more pressure resistant. Because of their lighter weight and thin walls, they are
used in liquid transportation.
Advantages
 Seamless steel pipes have increased ability to withstand pressure.
 Seamless steel pipe is a continuous extrusion of the alloy, meaning
that it will have a round cross section that you can count on, which
is helpful when you’re installing pipes or adding fittings.
 Seamless pipes can perform well in harsh conditions, which means
that they can be used in extremely cold or hot environments.
❖ Welded Pipe
These products are typically made by forming strips
or plate into cylinders and seam-welding by various
methods. Manufacturing by welding permits the production
of larger diameter pipe than is possible with seamless
manufacturing methods, as well as larger diameter/wall thickness ratios. Welded
pipes are not typically used in high-pressure projects and are heavier than
seamless pipes. They transport gas more often than liquid.
Advantages
 Welded pipes are typically more cost effective than their seamless
equivalents.
 Welded pipes are usually more readily available than seamless.
 The wall thickness of welded pipes is generally more consistent
than that of seamless pipes.
 The internal surface of welded tubes can be checked before
manufacturing, which isn’t possible with seamless.

A.2 Methods of Joining Pipes

Piping joints must be reliably leak-tight and provide adequate mechanical
strength to resist external loads due to thermal expansion, weight, wind, seismic
activity, and other factors. Joints for pipe buried in soil may be subjected to unique
external loads resulting from thermal expansion and contraction, settlement, and other
factors. Joint designs that permit rotation about an axis perpendicular to the
longitudinal axis of the pipe may be advantageous in certain situations.
Disassembly frequency and ease should be considered when selecting joining
methods. Ideally the method for joining piping system components provides:
 minimum installed cost
 maintains its integrity throughout the lifetime of the facility
 provides restraint against axial thrust due to internal pressure
 provides strength against external loads equal to that of the pipe
 permits unrestricted flow with minimum pressure drop
 free from crevices that may be detrimental to the product or contribute to
corrosion or erosion problems.
There are three (3) methods in joining pipes discussed. These are: welded joints,
branched connections and threaded joints.
❖ Welded Joints
The most widely used joint in
piping systems is the butt-weld joint.
In all ductile pipe metals which can be
welded, pipe, elbows, tees, laterals,
reducers, caps, valves, flanges, and V-
clamp joints are available in all sizes
and wall thicknesses with ends
prepared for butt welding. Joint strength equal to the original pipe (except for

work-hardened pipes which are annealed by the welding), unimpaired flow

pattern, and generally unimpaired corrosion resistance more than compensate
for the necessary careful alignment, skilled labor, and equipment required.
Socket-welded joints are not as resistant

to externally applied bending moments as are
butt-welded joints, are not easily examined by
volumetric nondestructive examination
methods such as radiography and ultrasonic,
and should not be used where crevice corrosion
has been determined to be of concern. However,
they are widely used in sizes 2 in and smaller and are quite satisfactory for most
applications when used within the limits established by code restrictions and
good engineering judgment.
❖ Branch Connections
Branch connections may be made with
manufactured tees, fabricated reinforced and
non-reinforced branch connections or
manufactured integrally reinforced branch
connections. Butt-welded fittings offer the best
opportunity for nondestructive examination; however, branch connections are
commonly specified for branches smaller than the header, and often best satisfy
the design and economic requirements.

❖ Threaded joints
Principal use of threaded joints
is in sizes 2 in. and smaller, in metals
for which the most economically
produced walls are thick enough to
withstand pressure and corrosion after
reduction in thickness due to
threading. For threaded joints over 2 in, assembly difficulty and cost of tools
increase rapidly. Careful alignment, required at the start of assembly and during
rotation of the components, as well as variation in length produced by diametral
tolerances in the threads, severely limits preassembly of the components.
Threading is not a precise machining operation, and filler materials known as
“pipe dope” are necessary to block the spiral leakage path.
B. Valves
Valves are an essential part of any piping system which serve the functions of
allowing, stopping, regulating, and controlling the flow, to fulfill the intended objectives
of the system. When fluid pressure builds up beyond a set limit, the valves relieve the
overpressure to safeguard the integrity of the piping system or a component. Valves
help in maintaining or breaking a vacuum. Valves also assist in maintaining the
pressure or temperature of the flow medium within the desired range or limit.

B.1 Classification Based on Mechanical Motion

Based on the mechanical or cyclical motion of the valve closure member, valves
are classified as follows:
❖ Linear Motion Valves
The valves in which the closure member, as in gate, globe, diaphragm, pinch,
and lift check valves, moves in a straight line to allow, stop, or throttle the flow.
(L-R) gate valve, globe valve, diaphragm valve, pinch valve and lift check valves
❖ Rotary Motion Valves
When the valve-closure member travels along an angular or circular path, as
in butterfly, ball, plug, eccentric- and swing check valves, the valves are called
rotary motion valves.

(L-R) butterfly valve, ball valve, plug valve and swing check valves
❖ Quarter Turn Valves

Some rotary motion valves require approximately a quarter turn, 0 through
90º, motion of the stem to go to fully open from a fully closed position or vice
versa.
The table provided summarizes the classification of valves based on the motion
of fluid.
Taken from the 7th ed. of Piping Handbook by Mohinder L. Nayyar

B.2 Selected Types of Valves

❖ Gate Valve
Gate valves are primarily designed to
serve as isolation valves. In service, these
valves generally are either fully open or
fully closed. When fully open, the fluid or
gas flows through the valve in a straight line with very little resistance. Gate valves
should not be used in the regulation or throttling of flow because accurate control is
not possible. Furthermore, high-flow velocity in partially opened valves may cause
erosion of the discs and seating surfaces. Vibration may also result in chattering of the
partially opened valve disc.
Advantages
 Gate valves have good shutoff characteristics.
 Gate valves are bidirectional (can be used in two directions)
 The pressure loss through the valve is minimal
Disadvantages
 Gate valves are not quick opening or closing valves. Full-stem travel to open
or close a gate valve requires many turns of its handwheel or an actuator.
 Gate valves require large space envelope for installation, operation, and
maintenance.
 The slow movement of the disc near the full-closed position results in high-
fluid velocities, causing scoring of seating surfaces, referred to as wire
drawing. It also causes galling of sliding parts.
Typical Applications
Socket or butt-welding end-gate valves in air, fuel gas, feed water, steam,
lube oil, and other systems are typical applications. Threaded-end gate valves may
be used in air, gaseous, or liquid systems. Concern for leakage from threaded
connection can be addressed by seal welding the threaded connection or by using

thread sealants, as appropriate. In low-pressure and low-temperature systems

such as fire protection systems’ water piping or water distribution pipelines,
flanged gate valves are commonly used.
❖ Globe Valve
Conventional globe valves may be used for
isolation and throttling services. Although these
valves exhibit slightly higher pressure drops than
straight-through valves (e.g., gate, plug, ball, etc.),
they may be used where the pressure drop through
the valve is not a controlling factor
.
Advantages
 Good shutoff capability

 Moderate to good throttling capability
 Shorter stroke (compared to a gate valve)
 Available in tee, wye, and angle patterns, each offering unique capabilities
Disadvantages
 Higher pressure drop (compared to a gate valve)

 Requires greater force or a larger actuator to seat the valve (with pressure
under the seat)
 Throttling flow under the seat and shutoff flow over the seat
1. Cooling water systems where flow needs to be regulated
2. Fuel oil system where flow is regulated and leak tightness is of
importance.

3. High-point vents and low-point drains when leak tightness and safety are
major considerations.
4. Feed water, chemical feed, condenser air extraction, and extraction drain
systems.
5. Boiler vents and drains, main steam vents and drains, and heater drains.
❖ Ball Valves
The ball valve is a quarter-turn valve
suitable for clean gas, compressed air, and
liquid service. They also can be used for
slurry service, but provisions for prevention
of crud build-up must be made. The use of
soft-seat materials such as nylon, delrin,
synthetic rubbers, and fluorinated polymers imparts excellent sealing ability. With
fluorinated polymer seats, ball valves can be used for service temperatures ranging
from 450 to 500ºF (270º to 260ºC); with graphite seats, service temperatures to
1000ºF (538ºC) or even higher are possible. Also, with metal-backing seats, the valves
can be used in fire-safe services. Ball valves are nonbinding and provide leak-tight
closure. The valves exhibit negligible resistance to flow because of their smooth body
and port.
Advantages
 Provides bubble-tight service

 Quick to open and close
 Smaller in size than a gate valve
 Lighter in weight than a gate valve.
 Can be used in clean and slurry applications.
 High-quality ball valves provide reliable service in high-pressure and high-
temperature applications.
Disadvantages

 They are not suitable for sustained throttling applications

 In slurry or other applications, the suspended particles can settle and
become trapped in body cavities causing wear, leakage, or valve failure
1. Air, gaseous, and liquid applications requiring bubble-tight service
2. Low-point drains and high-point vents in liquid, gaseous, and other fluid
services
3. Instrument root valves
4. Cooling water, feed water and steam systems
❖ Plug Valve
Plug valves, also called cocks, generally are used
for the same full-flow service as gate valves, where
quick shutoff is required. Plug valves are not generally
designed for the regulation of flow. Nevertheless, in
some applications, specially designed plugs are used
for this purpose, particularly for gas-flow throttling.
Plug valves generally can be readily repaired or cleaned without necessitating

removal of the body from the piping system. They are available for pressure service
from vacuum to 10000 psi (69000 kPa) and temperatures from 50 to 1500ºF (46 to
816ºC). Also, plug valves are available with a wide variety of linings suitable for many
chemical service applications.
Advantages
 Simple design with few parts
 Quick to open or close.
 Can be serviced in place.

 Offers minimal resistance to flow.

 Provides reliable leak-tight service. Seal can be maintained by injection of
sealant or by replacement of sleeve, in addition to utilizing the wedging
action of a tapered plug.
 Multiple port design helps reduce number of valves needed and permits
change in flow direction.
Disadvantages
 Requires greater force to actuate, due to high friction
 NPS 4 (DN 100) and larger valves require use of actuators
 Reduced port, due to tapered plug
 Typically, plug valves may cost more than ball valves
Typical applications
As indicated earlier, the plug valves can be and have been used in many
different fluid services. They perform well in slurry applications. They are primarily
used in bubble-tight services as on-off stop valves. The wiping-off action of a plug
does not permit suspended particles to accumulate and form crud. The following
are some typical applications of plug valves:
1. Air, gaseous, and vapor services
2. Natural gas piping systems
3. Coal slurries, mineral ores, mud, and sewage applications
4. Oil piping systems 5. Vacuum to high-pressure applications
❖ Diaphragm Valves
These valves consist of a rigid body formed with a weir placed in the flow path, a
flexible diaphragm which forms the upper pressure boundary of the valve, a
compressor which is used to force the diaphragm against the weir, and the bonnet and
hand-wheel which secure the diaphragm to the body and actuate the compressor.
Diaphragm valves are available in a wide choice of body, diaphragm, and lining
materials that are suitable for service with a wide variety of chemicals. For severe

corrosive applications, diaphragm valves are made of stainless steel or PVC plastics,
or they are lined with glass, rubber, lead, plastics, titanium, or still other materials.
Some of the common materials used for diaphragms are listed in table given.
Advantages
 Can be used as on-off and throttling service valves
 Offer good chemical resistance due to variety of linings available
 Stem leakage is eliminated
 Provides bubble-tight service
 Does not have pockets to trap solids, slurries, and other impurities. It is
suitable for slurries and viscous fluids
 These valves are particularly suitable for hazardous chemicals and
radioactive fluids
 These valves do not permit contamination of flow medium, thus they are
used extensively in food processing, pharmaceutical, brewing, and other
applications which cannot tolerate any contamination.
Disadvantages
 The weir may prevent full drainage of piping\
 Working temperatures and pressures are limited by the diaphragm
material. Generally, the pressures are limited to 200 psi (1380 kPa) and
temperatures up to 400ºF (204ºC)
 The diaphragm may also limit the hydrostatic pressure.
 The diaphragm may experience erosion when used extensively in severe
throttling service containing impurities
 Diaphragm valves are available in limited sizes, usually NPS ¹⁄₂ to 12 (DN
15 to 300).
1. Clean or dirty water and air service applications

2. Demineralized water systems

3. Corrosive applications
4. Radwaste systems in nuclear facilities
5. Vacuum service
❖ Butterfly Valves
Butterfly valves are used to control and regulate or
throttle the flow. They are characterized by fast operation
and low-pressure drop. They require only a quarter-turn from
closed to full-open position. A butterfly valve has a short
circular body, a round disc, shaft, metal-to-metal or soft
seats, top and bottom shaft bearings, and the stuffing box. Sometimes butterfly valves
are manufactured in rectangular or square configurations.
Advantages
 The compact design requires considerably less space, compared to gate,
globe, or other valves
 Light in weight
 Quick acting; as a quarter-turn valve, it requires less time to open or close
 It is available in large sizes, ranging from NPS 1¹⁄₂ (DN 40) to over NPS
200 (DN 5000)
 They have low-pressure drop and high-pressure recovery
 Provide bubble-tight service.
Disadvantages
 Throttling service is limited to low differential pressure
 Throttling is restricted to a 30- to 80-degree disc opening. Location of
valve, pipe routing, free, and closed discharge are to be considered while
using a butterfly valve in a throttling application
 Cavitation and choked flow are two potential concerns
 The disc movement is unguided and affected by flow turbulence

Concentric or low-pressure and low-temperature butterfly valves, the high-
performance butterfly valves, cover a wide range of applications. These
applications include:
1. Cooling water, air, gases, and other similar applications, such as fire
protection, circulating water, etc.
2. Corrosive services requiring lined valves
3. Food processing, chemical, and pharmaceutical services
4. Slurry and similar services
5. High-pressure and high-temperature water and steam services
❖ Check Valves
Check valves are designed to pass flow in one direction with minimum resistance
and to prevent reverse or backflow with minimal leakage. Check valves are available
in sizes from NPS ¹⁄₄ (DN 6) through NPS 72 (DN 1800). Other sizes may be made
available to meet specific size requirements. Depending upon the design requirements
of a piping system, a check valve may have butt welding, socket welding, threaded, or
flanged ends.
Advantages
 Check valves are self-actuated
 Check valves require no external means to actuate the valve either to
open or close.
 Check valves are fast acting
Disadvantages
 Since all moving parts are enclosed, it is difficult to determine whether
the valve is open or closed. Furthermore, the condition of internal parts
cannot be assessed.
 Each type of check valve has limitations on its installation configurations

 Valve disc can stick in open position.
C. Fittings
Directional changes in piping systems are typically made with bends or welded
fittings. Bends are made as either hot bends or cold bends. Cold bending is done at
temperatures below the material transformation temperature. Depending on the
material and the amount of strain involved, annealing or stress relief may be required
after bending.
Pipe fittings are either male fittings or female fittings. In threaded pipe fittings,
female threads are on the inside while male threads are on the outside. Pipe fittings
that have one female end and one male end are called street fittings. Pipe fittings are
used to connect pipes or tubes in two ways:
• By threading: Threaded pipes screw together to connect or join. Generally metal

pipes are threaded and they have threaded fittings.
• By slip fit: Slip fit pipes use sleeves that slip into one another. The plastic pipes
are either threaded or slip fit.

C.1 Purpose of a Pipe Fitting

The basic purposes of any pipe fitting are as follows:
 Connecting the bores of two or more pipes or tubes.
 Connecting pipe sections.
 Connecting a pipe to a different apparatus.
 Changing the direction of fluid/liquid flow.
 Maintaining or regulating the flow.
 Closing and sealing a pipe.
C.2 Types of pipe fittings

❖ Pipe fittings to extend or terminate pipe runs and connect pipes
Couplings
Adapters

Unions
Caps and Plugs
Flanges
❖ Fittings to change a pipe's direction
45º elbow
90º elbow
❖ Pipe fittings to split the fluid flow

Tees
Cross
Wyes
❖ Pipe fittings to change pipe size
Reducers
FACTORS TO BE CONSIDERED
The following items should be considered by the engineer when developing the
design for a piping system:
1. Properties and characteristics of fluid being conveyed

2. Materials of construction
3. Effects of temperature level and temperature changes
4. Support and anchorage
5. Alterations in the system and the service
6. Maintenance and inspection
7. Ease of installation

8. Auxiliary or stand-by pumps and lines

9. Safety
a. Design factors
b. Relief valves and flare systems
PARTS OF PIPING LAYOUT
Identification of parts needed for design will generally give you an outlook on
what you are about to design. This will incorporate chemical engineering principles in
line with what is required as a standard. Determining this will also set your focus on
what parameter must be firstly acquired.
This image shows a picture of several component of one part in a piping system.
But in general, fluid, pipe, valves, fittings, fasteners, measuring devices and pump are
the basic and most important parts of piping system. This will determine what are
needed in your design.
7
5 3
6
4
2
PARTS DESCRIPTION
1. Fluid Material that is being transported
2. Pipe Material where the fluid is being transported

3. Fittings Provides connections and turns for pipes

4. Fasteners Holds the pipes in place
5. Valves Used to control the flow
6. Pumps Apply pressure difference for fluid flow
7. Measuring
Used for measuring the parameters needed
Devices
PRINCIPLES IN PIPING DESIGN
After knowing and identifying the parts, we must know underlying principles and
the method of designing the piping system.
FLUIDS
Properties and Behavior
Transportation and the storage of fluids (gases and liquids) involve the
understanding of the properties and behavior of fluids. Flows can be classified into two
major categories: (a) incompressible and (b) compressible flow. Most liquids fall into
the incompressible flow category, while most gases are compressible in nature. A
perfect fluid can be defined as a fluid that is nonviscous and nonconducting. Fluid flow,
compressible or incompressible, can be classified by the ratio of the inertial forces to
the viscous forces. This ratio is represented by the Reynolds number (NRe).
𝐷𝜈𝜌
𝑁𝑅𝑒 =
𝜇
where, ρ is the density of the fluid, V the velocity, D the diameter, and μ the
viscosity of the fluid. At a low Reynolds number, the flow is considered to be laminar,
and at high Reynolds numbers, the flow is considered to be turbulent.

Materials of Construction
Materials of construction will determine the required property of the pipe that
will not allow any damage in terms of corrosion, thermal expansion and even internal
and external stress.
Standards allow designers and users of materials to work with confidence that
the materials supplied will have the expected minimum properties. A few of the
organizations which generate standards of major importance to the chemical-process
industries in the United States are listed below.
1. American National Standards Institute (ANSI), formerly American Standards

Association (ASA). ANSI promulgates the piping codes used in the chemical-
process industries.
2. American Society of Mechanical Engineers (ASME). This society generates

the Boiler and Pressure Vessel Codes.
3. American Society for Testing and Materials (ASTM). This society generates
specifications for most of the materials used in the ANSI Piping Codes and the
ASME Boiler and Pressure Vessel Codes.
4. International Organization for Standardization (ISO). This organization is

engaged in generating standards for worldwide use. It has 80 member nations.

Tables for consideration in choosing the material of construction:
PIPE
Sizing
The design engineer must specify the diameter of pipe that will be used in given
piping system, and economic factors must be considered in determining the optimum
pipe diameter.
For turbulent flow (NRe > 2100) in steel pipes
Di,opt = 3.9𝑞𝑓 0.36 𝜌0.18
For viscous flow (NRe < 2100) in steel pipes

Di,opt = 3.9𝑞𝑓 0.36𝜇𝑐 0.18

where, Di.opt = optimum inside pipe diameter, in.
qf = fluid flow rate, ft3/s
ρ = fluid density, lb/ft3
μc= fluid viscosity, centipoises
Pipe Strength
Iron and steel pipes were originally classified on the basis of wall thickness as
standard, extra-strong, and double-extra-strong. Modem industrial demands for more
exact specifications have made these three classifications obsolete. Pipes are now
specified according to wall thickness by a standard formula for schedule number as
designated by the American Standards Association.
The bursting pressure of a thin-walled cylinder may be estimated from the

following equation:

2 ST tm
Pb =
Dm
where, Pb = bursting pressures (difference between internal and external pressures),psi
ST = tensile strength, psi
tm= minimum wall thickness, in.
Dm = mean diameter, in.
Nominal Pipe Diameter
Pipe sizes are based on the approximate diameter and are reported as nominal
pipe sizes. Although the wall thickness varies depending on the schedule number, the
outside diameter of any pipe having a given nominal size is constant and independent
of the schedule number. This permits the use of standard fittings and threading tools
on pipes of different schedule numbers.

VALVES, FITTINGS AND FASTENERS
Valves are mechanical devices that control the flow and pressure within a
system or process. They are essential components of a piping system that conveys
liquids, gases, vapours, slurries etc. Some valves are self-operated while others
manually or with an actuator or pneumatic or hydraulic is operated. Its functions were
to slow down or stop the flow of a fluid, to reduce or increase the flow rate of a fluid,
to control the direction of a flow and to regulate process pressure.
Pipe fittings are widely demanded for any piping and plumbing systems used in
industrial and commercial applications. Fittings allow pipes to be joined or installed in
the appropriate place and terminated or closed where necessary. Fittings are available
in various shapes and sizes. They can be expensive, require time, and different
materials and tools to install. They are an essential part of piping and plumbing
systems. There are thousands of specialized fittings manufactured. Each type of pipe
or tube requires its own type of fitting, but usually all pipe fittings share some common
features. Pipe fittings are available everywhere where plumbing materials are sold.
A fastener is a hardware device that mechanically joins or affixes two or more

objects together. In general, fasteners are used to create non-permanent joints; that
is, joints that can be removed or dismantled without damaging the joining components.
There are three major steel fasteners used in industries: stainless steel, carbon steel,
and alloy steel. The major grade used in stainless steel fasteners: 200 series, 300
series, and 400 series. Titanium, aluminum, and various alloys are also common
materials of construction for metal fasteners. In many cases, special coatings or
plating may be applied to metal fasteners to improve their performance characteristics
by, for example, enhancing corrosion resistance. Common coatings/platings include
zinc, chrome, and hot dip galvanizing.
Frictional Loss
Frictional effects are extremely important in flow processes. In many cases

friction may be the main cause for resistance to the flow of a fluid through given

system. Consider the common example of water passing through a pipe. If no

frictional effects were present, pipes of very small diameters could be used for all
flow rates.
Approximate equations showing the relationship between the friction factor

and the Reynolds number in the turbulent-flow region have been developed. Two of
these equations follow:
For smooth pipe or tubes,
0.046
f =
(N Re )0.2
For new iron or steel pipe,
0.04
f =
(N Re )0.16
Fanning Equation
If the linear velocity, density, and viscosity of the flowing fluid remain constant
and the pipe diameter is uniform over a total pipe length L, the equation will give:

−p f 2 fV 2 L
F= =
 gc D
PUMPS/COMPRESSORS
Pump Selection
Pumps are used to transfer fluids from one location to another. The pump
accomplishes this transfer by increasing the pressure of the fluid and, thereby,
supplying the driving force necessary for flow. The different types of pumps commonly
employed in industrial operations can be classified as
1. Reciprocating or positive-displacement pumps with valve action: piston pumps,

diaphragm pumps, plunger pumps
2. Rotary positive-displacement pumps with no valve action: gear pumps, lobe pumps,
screw pumps, eccentric-cam pumps, metering pumps
3. Rotary centrifugal pumps with no valve action: open impeller, closed impeller, volute
pumps, turbine pumps
4. Air-displacement systems: air lifts, acid eggs or blow cases, jet pumps, barometric
legs

Many different factors can influence the final choice of a pump for a particular
operation. The following list indicates the major factors that govern pump selection:
1. The amount of fluid that must be pumped. This factor determines the size of pump
(or pumps) necessary.
2. The properties of the fluid. The density and the viscosity of the fluid influence the
power requirement for a given set of operating conditions; corrosive properties of
the fluid determine the acceptable materials of construction. If solid particles are
suspended in the fluid, this factor dictates the amount of clearance necessary and
may eliminate the possibility of using certain types of pumps.
3. The increase in pressure of the fluid due to the work input of the pumps. The head
change across the pump is influenced by the inlet and downstream-reservoir
pressures, the change in vertical height of the delivery line, and frictional effects.
This factor is a major item in determining the power requirements.

4. Type of flow distribution. If nonpulsating flow is required, certain types of pumps,

such as simplex reciprocating pumps, may be unsatisfactory. Similarly, if operation
is intermittent, a self-priming pump may be desirable, and corrosion difficulties may
be increased.
5. Type of power supply. Rotary positive-displacement pumps and centrifugal pumps
are readily adaptable for use with electric-motor or internal-combustion-engine
drives; reciprocating pumps can be used with steam or gas drives.
6. Cost and mechanical efficiency of the pump.
Power Requirements
A major factor involved in the design of pumping and piping systems is the
amount of power that is required for the particular operation. Mechanical power must
be supplied by the pump to overcome frictional resistance, changes in elevation,
changes in internal energy, and other resistances set up in the flow system. The various
forms of energy can be related by the total energy balance or the total mechanical-
energy balance.
In differential form,

g V dV
dZ + vdP + i i = SWs −  F
gc gc
where, g = local gravitational acceleration, usually taken as 32.17 ft/s2

gc = conversion factor in Newton’s law of motion, 32.17 ft * lbmmass/(s2 )(lbf)
Z = vertical distance above an arbitrarily chosen datum plane, ft
v = specific volume of the fluid ft3/lbm
p = absolute pressure, Ibf/ft*
I = instantaneous or point velocity, ft/s
u = internal energy, ft *Ibf/lbm
Q = heat energy imparted as such to the fluid system from an outside source, ft *Ibf/lbm
W = shaft work, gross work input to the fluid system from an outside source, ft *Ibf/lbm
W, = mechanical work imparted to the fluid system from an outside source,* ft *lbf/lbm
F = mechanical-energy loss due to friction, ft. Ibf/lbm
To cause liquid to flow, work must be expended. A pump may raise the liquid to
a higher elevation, force it into a vessel at higher pressure, provide the head to
overcome pipe friction, or perform any combination of these. Regardless of the service
required of a pump, all energy imparted to the liquid in performing this service must
be accounted for; consistent units for all quantities must be employed in arriving at the
work or power performed.
MEASURING EQUIPMENT
Flow
Orifice meters, venturi meters, rotameters, and displacement meters are used
extensively in industrial operations for measuring the rate of fluid flow. Other flow-
measuring devices, such as weirs, pitot tubes, anemometers, and wet-test meters, are
also useful in industrial operations.

where qf = flow rate, ft”/s

Cd= coefficient of discharge
Sc = cross-sectional flow area at point of minimum cross-sectional flow area, ft’
S1= cross-sectional flow area in upstream section of duct before constriction, ft2
gc = gravitational constant in Newton’s law of motion, 32.17 ft *Ibm/WsXlbf)
g = local gravitational acceleration, ft/(s2)
v = average specific volume of fluid, ft3/lb
p1 = static pressure in upstream section of duct before constriction, psf
pc = static pressure at point of minimum cross-sectional flow area, psf
VP = volume of plummet, ft3
SP = maximum cross-sectional area of plummet, ft2
p, = density of plummet, lb/ft3
Temperature
For most points requiring temperature monitoring, either thermocouples or resistive

thermal detectors (RTDs) can be used. Each type of temperature transducer has its
own advantages and disadvantages, and both should be considered when
temperature is to be measured. Since there is considerable confusion in this area, a
short discussion of the two types of transducers is necessary.
Thermocouples
The various types of thermocouples provide transducers suitable for

measuring temperatures from −330 to 5000°F (−201 to 2760°C).
Thermocouples function by producing a voltage proportional to the temperature
differences between two junctions of dissimilar metals. By measuring this
voltage, the temperature difference can be determined. It is assumed that the
temperature is known at one of the junctions; therefore, the temperature at the

other junction can be determined. Since the thermocouples produce a voltage,

no external power supply is required to the test junction.
Resistive Thermal Detectors (RTDs)
RTDs determine temperature by measuring the change in resistance of

an element due to temperature. Platinum is generally utilized in RTDs because
it remains mechanically and electrically stable, resists contaminations, and can
be highly refined. The useful range of platinum RTDs is −454–1832°F
(−270−1000°C). Since the temperature is determined by the resistance in the
element, any type of electrical conductor can be utilized to connect the RTD to
the indicator.
PIPING SYSTEM LAYOUT
There are certain general principles that should be adhered to in the design of
piping systems as well as the selection and application of fittings. Some of the following
are:
 Wherever possible, pipe lines should be run in straight lines with right-angled
turns. It is undesirable to run a pipe lines at odd angles even though it shortens
the line and reduces the number of fittings.
 When a pipe makes a right-angled turn, it is good practice to use a tee with one
opening closed by a pipe plug or cap or a cross with two closed openings rather
than an elbow. This will permit subsequent connections without breaking a
number of joints and will facilitate cleaning.

 For connections that are not feasible with the right-angles turns, the use of two
45° elbows is suggested for most cases.
 For screwed fittings, pipe should be carefully cut to the proper length and the
interior edge burred or reamed to prevent constriction and sharp edges.
 Special fabricated fittings such as expansion bends and coiled piping must be
carefully specified so that they will fit properly.

 In all piping systems, valves should be installed in such a manner that they
may be repacked, if necessary, without closing the line. Valves should not be
used to brace a pipe or carry the weight of the line, since distortion of the valve
may result in inefficient operation and require an excessive amount of
maintenance.
DESIGN PROCEDURE
Establish the location of the pipelines: its source and destination, required bends, the
terrain over which it will pass.
1. Determine the total length of straight pipeline and all the fittings required.
2. Establish the characteristics of the fluid to be carried, including its density,
viscosity, and amount.
3. From the piping design equations given by Peters and Timmerhaus, calculate
the time of transport
4. Calculate the pipe dimensions, of which the diameter and wall thickness is
inclusive of
5. Calculate the total head, including friction losses, potential, kinetic, and
pressure heads
6. Calculate for the net positive suction head (NPSH)
7. Calculate for the power requirement of the pump

SAMPLE PIPING DESIGN
DESIGN PROBLEM
Wastewater amounting to 107,976.96 kg/batch needs to be transported to the
neutralization contact basin from the flow equalization basin. Design a piping system
of optimal aspects and dimensions.
DESIGN DESCRIPTION
Wastewater from the process equipment is conveyed using a piping system to
the wastewater receiving basin to be treated in the subsequent processes. A pump
provides the required head to transport the fluid and a valve is used to regulate the
flow. Valves and fittings modify, control, and regulates the flow.
DESIGN SELECTION
Among the choices of piping material, carbon steel is chosen as it is the most
compatible and suitable material in handling a wide variety of common chemical
substances. (Metcalf and Eddy). For general conveying of liquids with water-like
properties, low pressure drop, and short to medium distances, a single centrifugal
pump is most suitable (Peters and Timmerhaus). Globe valves are used for general
conveying of dirty liquids with water-like properties with or withouth throttling required
(Process Equipment Design)
DATA AND ASSUMPTIONS
1. The system is ideal; thus, fluid flow is incompressible and isothermal

2. The piping system includes one (1) standard elbow, one (1) globe valve, and
one (1) centrifugal pump
3. The mass flow rate of wastewater is 1059.06 kg/m3 /batch (Basis: Material
Balance)
4. The density of wastewater is 1059.06 kg/m3 (Basis: Experimental Study)
5. The viscosity of wastewater is 2 cp (Basis: Experimental Study)

6. The vapor pressure of water-like liquids is assumed to be that of water,

3.168kPa (Transport Processes and Unit Operation by Geankoplis, Appendix
A.2-2 p.854)
7. The total straight pipe length 12m (39.3701 ft)
DESIGN CONSIDERATION
1. The material of construction of pipeline is carbon steel. (Metcalf and Eddy)
2. The fluid velocity recommended for water-like fluids ranges from 1.0 to 3.0 m/s.
Fluid velocity of 1.0 m/s is considered (Plant Design and Economics for
Chemical Engineers by Peters and Timmerhaus 5th Ed., Table 12-3, p.501)
3. The efficiency of centrifugal pumps is 45% at 100 gpm, 70% at 500 gpm, 80%
at 10,000 gpm (Chemical Process Equipment by Couper, p. xviii)
DESIGN REQUIREMENTS
1. Time of Transport c. Kinetic Head
2. Pipe Dimensions d. Pressure Head
3. Total Head 4. Net Positive Suction Head
a. Friction Losses (NPSH)
b. Potential Head 5. Power Requirement

Wastewater Piping Layout
DESIGN CALCULATIONS
1. Time of Transport
In computing for the piping time, the optimum diameter equation for turbulent flow
by Timmerhaus (Chemical Engineering Design 5th Ed., Equation 12-15 p. 501) and
the fluid velocity formula is used. The optimum diameter formula is,
𝐷𝑖,𝑜𝑝𝑡 = 0.363𝑄 0.45 𝜌0.13 (1)
where
Di,opt = optimum diameter
Q = volumetric flowrate
ρ = the fluid density
The fluid velocity formula is,
𝑄
𝑣= (2)
𝐴
where
v = fluid velocity
A = cross-sectional area of pipe
Q = volumetric flowrate
Elaborating equation (2),

𝑚
𝜌𝑡
𝑣= 𝜋 (3)
𝐴 4 𝐷𝑖,𝑜𝑝𝑡 2
By relating equations (1) and (3), the diameter variable is eliminated and the
time variable can be isolated, giving,
10
9.6627𝑚0.10
𝑡=( ) (4)
𝑣𝜌0.36
Subtituting know values to equation (4)

10
9.6627(107,976.96 kg)0.10
𝑡=
𝑚 𝑘𝑔 0.36
(1.0 𝑠 ) (1059.06 3 )
( 𝑚 )
𝑚𝑖𝑛
𝑡 = 9876.48 𝑠 ×
60𝑠
𝑡 = 164.61 𝑚𝑖𝑛
Use = 165 minutes
2. Pipe Diameter
The volumetric flowrate is first calculated as,
𝑉
𝑄=
𝑡
107,976.96 𝑘𝑔
( )
𝑘𝑔
1059.06 3
𝑄= 𝑚
9876.48𝑠
𝑚3
𝑄 = 0.0103
𝑠
Substituting know and calculated values to equation (1),
𝐷𝑖,𝑜𝑝𝑡 = 0.363𝑄 0.45 𝜌0.13
0.45
𝑚3 𝑘𝑔 0.13
𝐷𝑖,𝑜𝑝𝑡 = 0.363 (0.0103 ) (1059.06 )
𝑠 𝑚3

39.37 𝑖𝑛
𝐷𝑖,𝑜𝑝𝑡 = 0.1146 ×
𝑚
𝐷𝑖,𝑜𝑝𝑡 = 4.5118 𝑖𝑛
Use: 5.0 in, Sch. 40
From Appendix A.5 of Principles of Transport Processes and Unit Operation by
Geankoplis (p.892), the standard dimensions of 5-in nominal pipe are,
Inner Outer
Nominal Pipe Thickness Cross-Sectional
Diameter Diameter
Size (in) Area (ft2)
(in) (in)
5 in. (Sch 40) 5.047 5.563 0.258 0.1390
3. Total Head
The total head is calculated using the mechanical energy balance:
∆v 2 g ∆P
−Ws = lw𝑓 + + ∆z +
2g c gc ρ
a. Friction Losses (lwf)
To solve for the friction loss, the friction loss formula by Brown is used (Unit
Operations, Equation 63, p.136):
𝑓𝐿𝑣 2
𝑙𝑤𝑓 =
2𝑔𝑐 𝐷
where
lwf = friction losses
f = friction factor
L = equivalent length of pipe
V = fluid velocity
D = internal diameter of pipe
The friction factor is calculated using the Colebrook-White Equation:

1 ε 2.52
= −2 log ( + )
√f 3.7D Nre √f

where
f = friction factor
ε = roughness (0.00015m for commercial steel pipes)
NRe = Reynold’s number
D = pipe diameter
Calculating for the Reynold’s number (Principles of Transport Processes and

Unit Operations by Geankoplis, Equation 2.5-1, p.49),
𝐷𝑣𝜌
𝑁𝑅𝑒 =
𝜇
1𝑚 𝑚 𝑘𝑔
(5.047 𝑖𝑛 × 39.37 𝑖𝑛) (1.00 𝑠 ) (1059.06 3 )
𝑚
𝑁𝑅𝑒 =
(0.002 𝑃𝑎𝑠)
𝑁𝑅𝑒 = 67,882.43
Substituting know values to the Colebrook-White Equation,
0.00015 𝑚
( 𝑚 )
1 5.047𝑖𝑛 × 39.37 𝑖𝑛 2.52
= −2 log +
√f 3.7 (67,882.43)√f
( )
𝑓 = 0.02362
The equivalent length (L) of the piping system is calculated using Figure 127 of
Unit Operations by Brown (p. 141)
𝐿 = 𝐿𝑠𝑡𝑟𝑎𝑖𝑔ℎ𝑡 𝑝𝑖𝑝𝑒 + 𝐿𝑔𝑙𝑜𝑏𝑒 𝑣𝑎𝑙𝑣𝑒 + 𝐿𝑠𝑡𝑑. 𝑒𝑙𝑏𝑜𝑤
3.28084 𝑓𝑡
𝐿 = (12 𝑚 × ) + 160 𝑓𝑡 + 14𝑓𝑡
𝑚
𝐿 = 213.37𝑓𝑡
Substituting known and calculated values to the friction loss formula,

𝑓𝐿𝑣 2
𝑙𝑤𝑓 =
2𝑔𝑐 𝐷
2
𝑚 1 𝑓𝑡
(0.02362)( 213.37𝑓𝑡) (1.0
𝑠 × 0.3048 𝑚)
𝑙𝑤𝑓 =
𝑙𝑏 − 𝑓𝑡 1 𝑓𝑡
2 (32.2 ) (5.047𝑖𝑛 × 12 𝑖𝑛)
𝑙𝑏𝑓 − 𝑠 2
𝑓𝑡 − 𝑙𝑏𝑓
𝑙𝑤𝑓 = 2.0026
𝑙𝑏𝑚
b. Potential Head
The potential head is calculated using the elevation in the piping system,
𝑔
∆𝑧 =0
𝑔𝑐
c. Kinetic Head
Since there are no reductions and enlargement in pipe size,
∆𝑣 2
=0
2𝑔𝑐
d. Pressure Head
Since the inlet and outlet of the piping system are both at atmospheric
pressure,
∆𝑃
=0
𝜌
Substituting the calculated values in the Mechanical Energy Balance,

∆𝑣 2 𝑔 ∆𝑃
−𝑊𝑠 = 𝑙𝑤𝑓 + + ∆𝑧 +
2𝑔𝑐 𝑔𝑐 𝜌
𝑓𝑡 − 𝑙𝑏𝑓
−𝑊𝑠 = (2.0026 + 0 + 0 + 0)
𝑙𝑏𝑚
𝑓𝑡 − 𝑙𝑏𝑓 1𝐽 2.2046 𝑙𝑏𝑚
−𝑊𝑠 = 2.0026 × ×
𝑙𝑏𝑚 1.35582 𝑓𝑡 − 𝑙𝑏𝑓 𝑘𝑔
𝐽
−𝑊𝑠 = 3.2563
𝑘𝑔

4. Net Positive Suction Head (NPSH)

The net head at the suction of the pump must exceed a certain value in order
to prevent formation of vapor and resulting to the cavitation of the metal.
The minimum head is called the net positive suction head and is calculated
using equation 7.13 from Walas (Chemical Process Equipment, pp. 133)
𝑁𝑃𝑆𝐻 = 𝜌(𝑊𝑠 ) − 𝑃𝑣𝑎𝑝𝑜𝑟
where
Ws = total head
Pvapor = vapor pressure of liquid
Substituting the known values,
𝑘𝑔 𝐽 1𝑁𝑚 1𝑃𝑎
𝑁𝑃𝑆𝐻 = (1059.06 ) (3.2563 × × ) − (3,168𝑃𝑎)
𝑚3 𝑘𝑔 1𝐽 1𝑁
𝑚2
𝑚3
𝑁𝑃𝑆𝐻 = 3445.45 𝑃𝑎 × = 3.2533 𝐽/𝑘𝑔
1059.06𝑘𝑔
Use: 3.25 J/kg
The theoretical power requirement is calculated based on the mass flowrate and
the total head:
𝑃𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 = 𝑚̇𝑊𝑠
107976.96𝑘𝑔 𝐽
𝑃𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 = ( ) (3.2563 )
9876.476212𝑠 𝑘𝑔
𝑃𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 = 35.60𝑊
Considering a pump efficiency of 45%,

𝑃𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙
𝑃𝑎𝑐𝑡𝑢𝑎𝑙 =
0.45
35.60 𝑊
𝑃𝑎𝑐𝑡𝑢𝑎𝑙 =
0.45

ℎ𝑝
𝑃𝑎𝑐𝑡𝑢𝑎𝑙 = 79.11 ×
745.7 𝑊
𝑃𝑎𝑐𝑡𝑢𝑎𝑙 = 0.1061 ℎ𝑝
Use = 0.25 hp
PIPING SYSTEM
OPERATING DATA
Wastewater Equalization Basin to Neutralization

Piping Connection
Contact Basin
Function Transport of Wastewater
Materials Handled Wastewater
Conveying Time 165 minutes
PIPE DATA
Material of Construction: Carbon Steel
Nominal Diameter 5.0 in., Sch 40
Outside Diameter 5.563 in
Inside Diameter 5.047 in
Wall Thickness 0.258 in.
Total Head 3.2563 J/kg
NPSH 3.25 J/kg
Power Requirement 0.25 hp
AUXILIARIES
1 standard elbow, 1 globe valve, 1 centrifugal pump

INSTRUMENTATION AND CONTROL

INTRODUCTION
Instrumentation is a collective term for measuring instruments used for

indicating, measuring and recording physical quantities, and has its origins in the art
and science of scientific instrument-making. The term instrumentation may refer to a
device or group of devices used for direct reading thermometers or, when using many
sensors, may become part of a complex industrial control system in such as
manufacturing industry, vehicles and transportation.
Control systems are used to maintain process conditions at their desired values
by manipulating certain process variables to adjust the variables of interest.
The type of control system shown in the figure is termed a closed-loop feedback
control system. Closed-loop refers to the fact that the controller automatically acts to
return the controlled variable to its desired value. In contrast, an open-loop system
would have the measurement signal disconnected from the controller, and the
controller output would have to be manually adjusted to change the value of the
controlled variable. An open-loop system is sometimes said to be in manual mode as
opposed to automatic mode (closed-loop).

DEFINITIONS
Block diagram — Diagram that indicates the flow of information around the control
system and the function of each part of the system.
Closed loop — In closed loop, the measured value of the controlled variable is fed back
to the controller.
Controlled variable — The process variable that we want to maintain at a particular

value.
Controller — A device that outputs a signal to the process based on the magnitude of
the error signal. A proportional controller outputs a signal proportional to the error.
Disturbance rejection—One goal of a control system, which is to enable the system to

“reject” the effect of disturbance changes and maintain the controlled variable at the
set point.
Disturbances — Any process variables that can cause the controlled variable to change.
In general, disturbances are variables that we have no control over.
Error — The difference between the values of the set point and the measured variable.
Manipulated variable — Process variable that is adjusted to bring the controlled

variable back to the set point.
Negative feedback — In negative feedback, the error is the difference between the set
point and the measured variable (this is usually the desired configuration).
Offset — The steady-state value of the error.
Open loop — In open loop, the measured value of the controlled variable is not fed back
to the controller.
Set point — The desired value of the controlled variable.

Block diagram indicates the flow of information around the control system and
the function of each part of the system.
TYPES OF CONTROLLERS
A. Proportional Control. The simplest type of controller is the proportional

controller. (The ON/OFF control is really the simplest). Its goal is to reduce
the error between the process output and the set point.

B. Proportional-Integral (Pi) Control. If we cannot tolerate any residual error, we

will have to introduce an additional control mode: integral control. The
integral mode ultimately drives the error to zero. This controller has two
adjustable parameters for which we select values, the gain and the integral
time.
C. Proportional-derivative (pd) control. Derivative control is another mode

that can be added to our proportional or proportional-integral controllers. It
acts upon the derivative of the error, so it is most active when the error is
changing rapidly. It serves to reduce process oscillations.
D. Proportional-integral-derivative (pid) control. This mode of control is a

combination of the previous modes.

Response of a typical control system showing the effects of various modes of control
TYPES OF SENSORS
A. Temperature Sensors
THERMISTOR. Thermistors are one of the most commonly used devices
for the measurement of temperature. Thermistors are thermal resistors. They
are resistors whose resistance changes with the temperature. There are two
kinds of thermistors,
Advantage of Thermistors
• Its negative temperature characteristics compensate on certain cases when

• ambient condition keeps on changing
• Also used for measurement of pressure, liquid level, power, etc.

• Used as controls, overload protectors, giving warnings, etc.

• Its high resistivity leads to very small errors compared to RTSs and
thermocouples
• They are smaller in size as compared to thermocouples.
• Thermistors provide faster response than RTDs.
• They offer high stability and brilliant repeatability.
Disadvantages of Thermistors
• Since thermistors are semiconductor devices, their operation is highly non

linear. This effect of nonlinearity needs to be compensated before applying
them in measurement circuits.
• Another disadvantage of thermistors is their limited temperature range due to
which they are rendered unsuitable for use at higher temperatures.
THERMOCOUPLES. Thermocouples are one of the simplest sensors
used in the industries for the purpose of temperature measurement. A
thermocouple is typically formed by connecting two wires of diverse metals (or
alloys) at one end. Between the two wires, a small output voltage is produced
at a given temperature.
Advantage of Thermocouples
• Extremely strong and robust

• Shock and vibration resistant
• Offers wide temperature range
• Easy to manufacture
Disadvantages of Thermocouples
• Thermocouples generate a quite low level output signal. Besides, the resulting
output tends to be non-linear due to which a sensitive and stable device is
needed for temperature measurement. The measuring device should be

capable enough to provide reference junction compensation and linearization

as well.
• Installation of a thermocouple also necessitates tremendous care so that the
possible noise sources could be diminished.
RESISTANCE TEMPERATURE DETECTOR. Their working is based upon
the “physical principle of the positive temperature coefficient of electrical
resistance of metals” which means that as the temperature of a material
increases, its electrical resistance will also increase in the direct proportion.
Advantage of Resistance Temperature Detector
• Unlike thermocouples, resistance temperature detectors operate in quite small

temperature domain. Their temperature span ranges from about -200 °C to a
maximum temperature of around 650 to 700 °C
• RTDs prove to be most accurate temperature sensors.
Disadvantages of Resistance Temperature Detector
• Their overall temperature range is very small.

• Their application involves high initial cost.
• They are not rugged enough to be used in high vibration environments
B. Pressure Sensors
THERMAL PRESSURE SENSOR. Thermal Pressure Sensor Uses the
changes in thermal conductivity of a gas due to density changes to measure
pressure. A common example of this type is the Pirani gauge. The Pirani gauge
is a robust thermal conductivity gauge used for the measurement of the
pressures in vacuum systems. It was invented in 1906 by Marcello Pirani.
RESONANT-WIRE PRESSURE SENSOR. An oscillator circuit causes the

wire to oscillate at its resonant frequency. A change in process pressure
changes the wire tension, which in turn changes the resonant frequency of the
wire. Resonant wire transducers can detect absolute pressures from 10 mm

Hg, differential pressures up to 750 in. water, and gauge pressures up to 6,000
psig (42 MPa).
C. Level Sensors
FLOAT SENSOR. Float sensors are so called because of its main system
that appears to float in the body of certain liquid substance.
Principle of Operation: A liquid level control system by using a float

sensor works on the principle of buoyancy, which states, “A float immersed in
a liquid is buoyed towards upward direction by an applied equal force to the
weight of the displaced liquid”. As a result, the body drives partially and gets
submerged upon the liquid surface and covers the same distance the liquid
level moves.
Construction: A level measurement float system consists of a float, a

sensor stem, a magnet, a reed switch and a weight suspended on the outside
of the open tank. A scale is fixed on the outside of the tank, and the contents
of the tank’s level are indicated by the position of the weight along the scale.
CAPACITANCE SENSOR. Capacitance level sensors are made available

for wide range of solids, aqueous, organic liquids and slurries. This technique
is frequently stated as the radio-frequency signals applied to a capacitance
circuit. The capacitive sensors are designed to sense material with dielectric
constants.
Principle of operation: The principle of capacitive level measurement is

based on the change of capacitance. There are two plates in capacitive sensor:
one plate acts as an insulated electrode and the other plate acts as a tank wall.
The capacitance depends on the liquid level. An empty tank has low
capacitance while a filled tank has higher capacitance. A simple capacitor
consists of two electrode plates separated by a small thickness of an insulator
such as solid, fluid, gas, or vacuum.

VIBRATING POINT LEVEL SENSOR. Single-probe vibrating level sensors

are ideal for bulk powder level. Since only one sensing element contacts the
powder, bridging between two probe elements is eliminated
Principle of Operation: This sensor uses the vibronic principle or to put

simply, the tuning fork principle. This principle uses the direct correlation
between oscillation and damping.
TYPES OF ACTUATORS
Actuators are a means by which a valve can be automated so that no

human interaction with the valve package is necessary to cycle the valve.
Actuators can be remotely operated and can act a shutdown mechanisms in
case of an emergency situation, wherein human interaction can be dangerous.
High Pressure Actuators
FEATURES:
• Can handle large flow

• Fast response, travel / flow indicator
• Suitable for High-Temperature Applications up to 121oC
• Multiple end connection options
OPERATION:
• Max. Outlet and Emergency Casing Pressures: 400psig / 27.6 bar

• Outlet Pressure Range: 5 to 300 psig / 0.35 to 20.7 bar
• Maximum Pressure Over Setpoint to Avoid Internal Parts Damage: 120
psig / 8.3 bar
Low Pressure Actuators
OPERATION:

• Max. Outlet and Emergency Casing Pressures: 70 psig / 4.8 bar

• Outlet Pressure Range: 5 to 300 psig / 0.35 to 20.7 bar
• Maximum Pressure Over Setpoint to Avoid Internal Parts
• Damage: 20 psig / 1.4 bar
Design Procedure
1. Describe and explain the equipment operation and the process control
operation of the equipment
2. Determine its controlled variables, manipulated variables and measuring

equipment
3. Determine the Controller Mode and Final Control Elements and explain why they
were selected
4. Identify the set points of the control system
5. Determine the control system of the equipment and create block diagrams
based on the number of the controlled variables.
SAMPLE DESIGN
Horizontal Paddle Dryer

Figure 8.54: Piping and Instrumentation Diagram of Horizontal Paddle Dryer

where: TT = temperature transmitter
TC = temperature control
FC = flow control
FT = flow transmitter
I. Operation
A. Equipment Operation
The horizontal paddle dryer is used to reduce the free moisture content of
tylose down to 9.6%. The horizontal paddle dryer are directly heated by electric
coils. The equipment is maintained under 105+/-5°C. A quality control officer
regularly checks the moisture condition of the dried tylose in every batch to confirm
that the moisture content is on the acceptable level and within the company's
specifications.
B. Process Control Operation
The equipment requires one process controls: temperature control. This
parameter was measured by resistance thermometer detector. Bulb-and-capillary
thermostat was used as the final control element. Proportional Integral Derivative
Controller is applied as it is the most versatile of all controller actions that can
respond quickly to changes (derivative mode), track required positions
(proportional mode), and reduce steady state errors (integral mode). Finally, a
feedback control closed-loop system is selected over the open-loop as it allows
corrective actions leading to the desired accuracy of parameters.
C. Mode of Operation: Batch Process
D. Residence Time: 1 hour
I. Equipment Control
A. Controlled Variables: Temperature
In drying the tylose, the temperature inside the horizontal paddle dryer must
be set at constant value. In this way, consistent quality of product with free moisture
content of less than 9.6% will be achieved.
B. Manipulated Variables: Electric Current

The dryer temperature is dictated by bulb-and-capillary thermostat for

electric current control.
C. Measuring Elements: Resistance Thermometer Detector
Figure 8.55: Measuring Elements Applied in Horizontal paddle dryer:

Resistance Thermometer Detector
To measure the temperature inside the dryer, a resistance thermometer
detector is installed. A resistance thermometer detector consists of a metal
conductor which measures electrical resistance that is calibrated in units of
temperature instead of units in ohms. This is selected over the other temperature
sensors as it is applicable for a temperature range of -80 to 320°C with a
measurement inaccuracy of only 0.5% which is 10 times more accurate than a
thermocouple (Perry's Chemical Engineering Handbook, 8th Edition by Perry and
Green, p. 8-56 to 8-57).
D. Controller Mode: Proportional Integral Derivative (PID) Controller
The PID controller, also known as the three mode controller, was adopted
in all the process controls of Esolite Chemicals Inc. It is the most versatile of all
controller actions. The proportional part of this controller multiplies the error by a
constant. The integral part integrates the error. Finally, the derivative part
differentiates the error. The functions of the individual proportional, integral, and
derivative controllers complement each other. The combination of the three results
to a system that responds quickly to changes, tracks required positions, and
reduces steady state errors. When the controller detects a detrimental change in
the system, the controller automatically integrates or derives the error back to the
setpoint.

E. Final Control Elements: One (1) Bulb-and-Capillary Thermostat
Figure 8.56: Final Control Elements Applied in Horizontal paddle dryer:

Bulb-and-Capillary Thermostat
For the temperature control a bulb-and-capillary thermostat was used as it
is applicable for sensor exposure temperature of -18 to 200°C (Omega
Engineering, 2017). Since the operating temperature of the horizontal paddle dryer
is only 105°C, then this particular instrument is suitable for the intended equipment.
F. Control System: Feedback Control Closed-Loop System

Feedback control closed-loop system utilizes loop structure with negative
feedback that brings a measurement to the desired setpoint. It is selected over the
open-loop as it allows corrective actions leading to the desired accuracy of
parameters. The block diagrams depicting the loops of flow and temperature
control are presented in Figure 8.57.
Figure 8.57: Loops for Temperature Control

G. Setpoints: 105°C
The temperature inside the horizontal paddle dryer is should be fixed at 105°C. A
variable change of 5% was considered for each parameter.
Acetic Acid Storage Tank
Figure 8.46: Piping and Instrumentation Diagram of Acetic Acid Storage Tank
where: LT = level transmitter LC = level control
I. Operation
The storage tank is used to store 1,787.89 kg acetic acid which is sufficient for
a 13-batch operation (137.53 kg/batch). The acetic acid is sourced from Czembi
Chemical in Kawit, Cavite and the refill of fluid inside the storage is done every week.
A normally open gate valve and spectacle blind is installed in the inlet line to allow the
introduction of acetic acid in the tank. A float-activated chain level gauge is used to
monitor the level inside the tank and it sends electric signal to the gate valve for the
control of acetic acid discharge. A centrifugal pump is used to transport the methanol
to the Nutsche filter 3.


The equipment requires one main process control: level control. This parameter
was measured using a float-activated chain level gauge. Control valve, particularly one
(1) gate valve, was used as the final control element. Proportional Integral Derivative
Controller is applied as it is the most versatile of all controller actions that can respond
quickly to changes (derivative mode), track required positions (proportional mode), and
reduce steady state errors (integral mode). Finally, a feedback control closed-loop
system is selected over the open-loop as it allows corrective actions leading to the
desired accuracy of parameters.
D. Residence Time: 24 hours
II. Equipment Control
A. Controlled Variable: Level
In storing acetic acid, the level is a vital parameter that must be set at constant
value. In this way, sufficient inventory of acetic acid is maintained and can be supplied
during the operation.
B. Manipulated Variable: Discharge Acetic Acid Flowrate
The acetic acid level is manipulated by opening or closing the gate valve
installed along the pipeline connecting the acetic acid storage tank and centrifugal
pump. This is to regulate the amount of acetic acid being discharged from the tank.
C. Measuring Element: Float-Activated Chain Level Gauge
Figure 8.47: Float-Activated Chain Level Gauge as Measuring Element Applied in the
Acetic acid Storage Tank
To monitor the acetic acid level, a float-activated chain level gauge is applied.
It consists of a float which rests on the surface of the liquid. The movement of the float

is transmitted to a pointer which indicates the liquid level on a calibrated scale. This
particular type of level indicator is low in cost, reliable, and operate over a large
temperature range (Instrumentation and Process Control, 2nd Edition by Kumar et al,
p. 24).
The mechanism of the float-activated chain level gauge depends on the liquid
level rise in the iso-butanol storage tank and the movement of the float installed. The
arm of the float causes the wiper to move over a potential divider whose output
terminals are connected to a voltmeter. As the float rises, a greater part of the potential
divider is included in the output circuit giving an increased output voltage. Hence, the
output voltage is directly proportional to the liquid level. The output terminals from the
potential divider is taken to a remote for display and is used to send electric signal to
the final control element.
The PID controller, also known as the three mode controller, was adopted in all
the process controls of Esolite Chemicals Inc. It is the most versatile of all controller
actions. The proportional part of this controller multiplies the error by a constant. The
integral part integrates the error. Finally, the derivative part differentiates the error.
The functions of the individual proportional, integral, and derivative controllers
complement each other. The combination of the three results to a system that
responds quickly to changes, tracks required positions, and reduces steady state
errors. When the controller detects a detrimental change in the system, the controller
automatically integrates or derives the error back to the setpoint.
E. Final Control Element: One (1) Gate Valve
Figure 8.48: Gate Valve as Final Control Element Applied in the Acetic Acid Storage
Tank

Control valves are the single most common type of final control element in a
process. For the level control of the methanol storage tank, a gate valve was used. The
actuators of these control valves are powered by an electric motor. Electric actuators
employ an electromagnet that move the stem which allows the valve to either be fully
opened or closed. The intensity of magnetic field created by the electromagnet is
influenced by the signals transmitted by the measuring elements. It offers the highest
precision-control positioning with an accuracy of +/- 0.000315 in. and a repeatability
of less than 0.0000394 in (Penton Corporate, 2017). Their setups are scalable for any
purpose or force requirement, and are quiet, smooth, and repeatable. Furthermore,
since there are no fluid leaks such as in the case of pneumatic or hydraulic actuators,
environmental hazards are eliminated.
open-loop as it allows corrective actions leading to the desired accuracy of the involved
parameter. The block diagram depicting the loop of level control was presented in
Figure 8.49.
Figure 8.49: Loop for Level Control

G. Setpoints: 137.53 kg acetic acid per batch
The level inside the iso-butanol storage tank is fixed by constant removal of
137.53 kg acetic acid per batch. A variable change of 5% was considered for this
parameter.

Alkalization Reactor
Figure 8.14: Piping and Instrumentation Diagram of the Alkalization Tank

where: PC = Pressure Control
PT = Pressure
Transmitter
TT = Temperature
Transmitter
TC = Temperature Control
LT = Level Transmitter
LC = Level Control

I. Operation
The alkalization tank is used to mix the ground abaca stripping waste and the
formulated 18% NaOH solution to produce a mixture containing alkali cellulose. This
is done by introducing first the 1,970.20 kg of NaOH solution to the top inlet nozzle of
the tank. Afterwards, 656.73 kg of abaca stripping waste are fed in the top opening of
the equipment via screw conveyor. Then, a process control engineer will switch on the
propeller agitator which is powered by an electric motor. A resistance thermometer
detector is mounted on the tank to ensure that the temperature is maintained at 70°C.
A C-spring Bourdon tube pressure gauge is mounted as well to vent a portion of the
vapor in case of occurrence of build-up pressure during the operation. Lastly, a float-
activated chain level gauge is installed to ensure that the process is operated within
the target liquid level limits.
The equipment requires three process controls: pressure control, temperature
control, and level control. These parameters were measured using C-spring Bourdon
tube pressure gauge, resistance thermometer detector, and float-activated chain level
gauge, respectively. Control valves, particularly two (2) gate valves, were used as the
final control elements for the pressure and level control system. On the other hand, for
the temperature control, a bulb-and-capillary thermostat is used.
Proportional Integral Derivative Controller is applied as it is the most versatile
of all controller actions that can respond quickly to changes (derivative mode), track
required positions (proportional mode), and reduce steady state errors (integral mode).
Finally, a feedback control closed-loop system is selected over the open-loop as it
allows corrective actions leading to the desired accuracy of parameters.
D. Residence Time: 1 hour
II. Equipment Control
A. Controlled Variables: Pressure, Temperature, and Liquid Level

In alkalization, the pressure, temperature, and liquid level inside the tank must
be set at constant value. In this way, consistent quality and quantity of alkalization
mixture will be obtained.
B. Manipulated Variables: Vent Vapor Flowrate, Electric Current, and Alkalization
Mixture Flowrate
The pressure inside the alkalization tank is manipulated by opening or closing
the gate valve installed in the vent pipeline. On the other hand, the temperature and
liquid level is manipulated by the bulb-and-capillary thermostat for electric current and
gate valve for the discharge alkalization mixture flowrate, respectively.
C. Measuring Elements: C-Spring Bourdon Tube Pressure Gauge, Resistance
Thermometer Detector, and Float-Activated Chain Level Gauge
a b c
Figure 8.15: Measuring Elements Applied in the Alkalization Tank

(a) C-Spring Bourdon Tube Pressure Gauge, (b) Resistance Thermometer
Detector, and (c) Float-Activated Chain Level Gauge
To monitor the pressure, a C-spring Bourdon tube pressure gauge is mounted
on the alkalization tank. This pressure-measuring device is made of stainless steel in
which the measured pressure deforms the material within its elastic limit and the
magnitude of deformation is approximately proportional to the applied pressure. This
was selected as it is the most widely used pressure sensing element that gives
accurate results, requires simple construction, and entails low cost. (Instrumentation
and Process Control, 2nd Edition by Kumar et al, p. 19)
On the other hand, to measure the temperature inside the alkalization tank, a
resistance thermometer detector is installed. A resistance thermometer detector
consists of a metal conductor which measures electrical resistance that is calibrated

in units of temperature instead of units in ohms. This is selected over the other
temperature sensors as it is applicable for a temperature range of -80 to 320°C with
a measurement inaccuracy of only 0.5% which is 10 times more accurate than a
thermocouple. Since the operating temperature of the alkalization tank is only 70°C,
then this particular instrument is deemed to be applicable for the intended equipment
(Perry's Chemical Engineering Handbook, 8th Edition by Perry and Green, p. 8-56 to 8-
57).
Lastly, to monitor the level of alkalization mixture, a float-activated chain level
gauge is applied. It consists of a float which rests on the surface of the liquid. The
movement of the float is transmitted to a pointer which indicates the liquid level on a
calibrated scale. This particular type of level indicator are low in cost, reliable, and
operate over a large temperature range (Instrumentation and Process Control, 2nd
Edition by Kumar et al, p. 24).
The mechanism of the float-activated chain level gauge depends on the liquid
level rise in the alkalization tank and on the movement of the float installed. The arm
of the float causes the wiper to move over a potential divider whose output terminals
are connected to a voltmeter. As the float rises, a greater part of the potential divider
is included in the output circuit giving an increased output voltage. Hence, the output
voltage is directly proportional to the liquid level. The output terminals from the
potential divider is taken to a remote for display and is used to send electric signal to
the final control element.
The PID controller, also known as the three mode controller, was adopted in all
the process controls of Esolite Chemicals Inc. It is the most versatile of all controller
actions. The proportional part of this controller multiplies the error by a constant. The
integral part integrates the error. Finally, the derivative part differentiates the error.
The functions of the individual proportional, integral, and derivative controllers
complement each other. The combination of the three results to a system that
responds quickly to changes, tracks required positions, and reduces steady state

errors. When the controller detects a detrimental change in the system, the controller
automatically integrates or derives the error back to the setpoint.
E. Final Control Elements: Two (2) Gate Valves and One (1) Bulb-and-Capillary
Thermostat
a b
Figure 8.16: Final Control Elements Applied in the Alkalization Tank

(a) Gate Valve and (b) Bulb-and-Capillary Thermostat
Control valves are the single most common type of final control element in a
process. For the pressure and level control of the alkalization tank, a gate valve was
used. The actuators of these control valves are powered by an electric motor. Electric
actuators employ an electromagnet that move the stem which allows the valve to either
be fully opened or closed. The intensity of magnetic field created by the electromagnet
is influenced by the signals transmitted by the measuring elements. It offers the
highest precision-control positioning with an accuracy of +/- 0.000315 in. and a
repeatability of less than 0.0000394 in (Penton Corporate, 2017). Their setups are
scalable for any purpose or force requirement, and are quiet, smooth, and repeatable.
Furthermore, since there are no fluid leaks such as in the case of pneumatic or
hydraulic actuators, environmental hazards are eliminated.
For the temperature control, on the other hand, a bulb-and-capillary thermostat
was used as it is applicable for sensor exposure temperature of -18 to 200°C (Omega
Engineering, 2017). Since the operating temperature of the alkalization tank is only
70°C, then this particular instrument is suitable for the intended equipment.

open-loop as it allows corrective actions leading to the desired accuracy of parameters.

The block diagrams depicting the loops of pressure, temperature, and level control
were presented in Figure 8.17.
(a)
(b)
(c)
Figure 8.17: Loops for (a) Pressure Control, (b) Temperature Control, and (c) Level
Control

G. Setpoints: 101.325 kPa, 70°C, and 2,626.93 kg alkalization mixture removal per
batch
The pressure, as well as the temperature and liquid level inside the alkalization
tank, is fixed at 101.325 kPa, 70°C, and 2,626.93 kg alkalization mixture removal per
batch, respectively. A variable change of 5% was considered for each parameter.
SUMMARY OF INSTRUMENTATION AND PROCESS CONTROL
Final
Controlled Measuring Manipulated Controlle
Equipment Control Setpoint
Variable Element Variable r Mode
Element
Resistance Bulb-and-
1. Horizontal Electric PID
Temperature Thermometer Capillary 105oC
Paddle Dryer Current Controller
Detector Thermostat
Float-
Discharge
2. Acetic Acid Activated Globe PID 137.53
Liquid Level Acetic Acid
Storage Tank Chain Level Valve Controller kg/batch
Flowrate
Gauge
C-Spring
Bourdon Tube Vent Vapor PID 101,325
Pressure Gate Valve
Pressure Flowrate Controller kPa
Gauge
Resistance Bulb-and-
3. Alkalization Electric PID
Temperature Thermometer Capillary 70oC
Reactor Current Controller
Detector Thermostat
Float- Discharge
Activated Alkalization PID 2,626.93
Liquid Level Gate Valve
Chain Level Mixture Controller kg/batch
Gauge Flowrate
Total Number of Resistance Thermometer Detector
Total Number of C-Spring Bourdon Tube Pressure Gauge
Total Number of Positive-Displacement Meter
Total Number of Float-Activated Chain Level Gauge
Total Number of Rotating Paddle Wheel Level Sensor
Total Number of Gate Valve
Total Number of Globe Valve
Total Number of Rotary Valve
Total Number of Bulb-and-Capillary Thermostat


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New Compiled Wastewater Report2

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TABLE OF CONTENTS

DESIGN OF WASTEWATER TREATMENT FACILITIES, PIPING SYSTEM, AND INSTRUMENTATION

• To design a Neutralization Contact Basin

DESIGN OF WASTEWATER TREATMENT FACILITIES, PIPING SYSTEM, AND INSTRUMENTATION

Primary treatment involves basic processes to remove suspended solid and

Neutralization is a common practice in wastewater treatment and waste

Neutralization is the process of adjusting the pH of water through the addition

DESIGN OF WASTEWATER TREATMENT FACILITIES, PIPING SYSTEM, AND INSTRUMENTATION

The design of a neutralization tank is concerned with the following

1. Influent wastewater properties

STEP-BY-STEP PROCEDURE IN DESIGNING A NEUTRALIZATION TANK

The step-by-step procedure in designing a neutralization tank is as follows:

1. Given the influent data, solve for the acid dosing

WASTEWATER TREATMENT PROCESS

In various chemical industries, the manufacturing of useful products also

DESIGN OF WASTEWATER TREATMENT FACILITIES, PIPING SYSTEM, AND INSTRUMENTATION

The wastewater treatment process of Esolite Chemicals Inc. includes collection

STATEMENT OF THE PROBLEM

The properties of the wastewater generated by Esolite Chemicals Inc. were

Table 9.1 Properties of Influent Wastewater

DESIGN OF WASTEWATER TREATMENT FACILITIES, PIPING SYSTEM, AND INSTRUMENTATION

To solve this problem, the manufacturing plant will employ a wastewater

DESIGN OF WASTEWATER TREATMENT FACILITIES, PIPING SYSTEM, AND INSTRUMENTATION

• To determine the processes suitable for the treatment of wastewater generated

Table 9.2 Standard Effluent Properties

DESIGN OF WASTEWATER TREATMENT FACILITIES, PIPING SYSTEM, AND INSTRUMENTATION

The wastewater facility is focused on reducing the pH, biological oxygen

The wastewater treatment process of the company is mainly consists of the

The influent incoming has a pH of 10.6. Neutralization contact basin is used to

DESIGN OF WASTEWATER TREATMENT FACILITIES, PIPING SYSTEM, AND INSTRUMENTATION

4. Anaerobic Process Treatment

5. Biological Degradation using Filter Media

The 103,328.27 kg of wastewater is treated in a trickling filter for 5.5 hours. A

6. Aerobic Process Treatment

DESIGN OF WASTEWATER TREATMENT FACILITIES, PIPING SYSTEM, AND INSTRUMENTATION

Table 9.3 Summary of Efficiency of Wastewater Treatment Equipment

DESIGN OF WASTEWATER TREATMENT FACILITIES, PIPING SYSTEM, AND INSTRUMENTATION

NEUTRALIZATION CONTACT BASIN

A total of 8998.08 kg per batch of wastewater is discharged from nutsche filter

Neutralization contact basin is used to neutralize the wastewater since it is

In every batch of production, a total of 8998.08 kg of wastewater is discharged

DESIGN OF WASTEWATER TREATMENT FACILITIES, PIPING SYSTEM, AND INSTRUMENTATION

DESIGN PARTS AND FUNCTIONS

Figure 9.10 Parts of the Neutralizaon Contact Basin

Table 9.14 Parts and Function of the Neutralization Contact Basin

DESIGN OF WASTEWATER TREATMENT FACILITIES, PIPING SYSTEM, AND INSTRUMENTATION

1. The amount of wastewater to be treated in the neutralization tank is

1. The material of construction to be used is reinforced concrete. (Metcalf and

1. HCl Dosing 5. Channel Width

DESIGN OF WASTEWATER TREATMENT FACILITIES, PIPING SYSTEM, AND INSTRUMENTATION

NaOH + HCl →NaCl + H20

HCL having a concentration of 35.2% with an equivalent weight of 36.5 (Metcalf

Since NaOH:HCl is 1:1,

𝑚𝑜𝑙𝑒𝑠 𝑁𝑎𝑂𝐻 = 𝑚𝑜𝑙𝑒𝑠 𝐻𝐶𝑙

𝑚𝑜𝑙𝑒𝑠 𝐻𝐶𝑙 𝑛𝑒𝑒𝑑𝑒𝑑 𝑡𝑜 𝑛𝑒𝑢𝑡𝑟𝑎𝑙𝑖𝑧𝑒 𝑡ℎ𝑒 𝑊𝑊 = 20.3911 𝑚𝑜𝑙𝑒𝑠 𝐻𝐶𝑙

DESIGN OF WASTEWATER TREATMENT FACILITIES, PIPING SYSTEM, AND INSTRUMENTATION

With 4 channels to be used, the total width must also be divided by 4 to

DESIGN OF WASTEWATER TREATMENT FACILITIES, PIPING SYSTEM, AND INSTRUMENTATION

DESIGN OF WASTEWATER TREATMENT FACILITIES, PIPING SYSTEM, AND INSTRUMENTATION

DESIGN OF WASTEWATER TREATMENT FACILITIES, PIPING SYSTEM, AND INSTRUMENTATION

The design of a clarifier is concerned with the following considerations:

Step-by-Step Procedure in Designing a Clarifier

The step-by-step procedure in designing a clarifier is as follows: