Operasional, Pemeliharaan &

Troubleshooting pada sistem IPAL

KARAKTERISTIK AIR LIMBAH DOMESTIK Penyaji:
MUHAMMAD ATJEMAIN, AMK, ST
Health Safety Environment
( Astra Group )
Topics

• Unit-unit proses di IPAL secara umum (General Treatment

Process)
• Tujuan Operasional & Pemeliharaan IPAL
• Jenis Pemeliharaan
• Aspek-aspek Operasional & Pemeliharaan (Key Aspects)
• Pemeliharan sistem IPAL & Troubleshooting
• Focus on Secondary Treatment Process (Conventional Activated
Sludge)
• Key Parameters to be maintained
• Include case study and calculation examples
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General Treatment Process (Flow Diagram)
Primar Secondar
Aerobic Reactor
Grit Oil & Grease y y Sand/Media
(i.e. Activated Disinfect
chamber Searator Clarifie Clarifier Filtration
Sludge i
Bar r Tank Tank
scree Process)
n
Secondary
Pre-treatment Tertiary
Treatment Return
treatment e

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Tujuan Operasional & Pemeliharan (O&M)
Jenis IPAL Jenis Treatment Process Tujuan O&M
• Mencapai optimum performance
(kinerja/efisiensi IPAL tinggi i.e. COD
Domestic removal efficiency
• Kualitas effluent yang bisa diterima
Physical (acceptable) untuk keperluan reuse
atau discharge (Baku mutu)
• Memastikan aktifitas pekerjaan
Biological perawatan berjalan secara teratur,
Industrial or
(aerobic/ efisien dan sustainable
Commercial
Anarobic) • Memperpanjang lifetime peralatan
IPAL
• Menghindari system collapse yang
Chemicals membahayakan kesehatan &
Gabungan lingkungan
Domestic + • Biaya OPEX rendah
Industrial

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Jenis Pemeliharaan (Maintenance):

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Aspek-aspek O&M IPAL(I)
• Design IPAL
• Apakah design kapasitas IPAL
sudah sesuai dengan load Action:
polutan-nya? - Evaluasi IPAL (i.e. sendiri
• Apakah teknologi yang dipilih
sudah atau oleh expert)
cocok dengan jenis limbahnya? - Adjust/upgrade sistem IPAL:
• Apakah spesifikasi peralatan sistem/peralatan/teknologi
sudah benar? yang lebih sesuai dengan
• Apakah ada perubahan dalam karakter limbahnya
flow atau load?

• Teknis
• Installed equipment:
• Flowmeter, pump, blower,
etc.
• Available maintenance tools,
simple portable measurement
devices (pH, DO meter),
operation manual and
maintenance procedure, etc.
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Aspek-aspek O&M (II-a)
• Kelengkapan data monitoring:
• Berkala (sebulan sekali)  lab analysis
(mengacu pada peraturan yang berlaku
KepMen LH)
Untuk mengetahui performance IPAL.
Misal: Hitung effisiensi COD removal:
𝐶𝑂𝐷𝑖𝑛−𝐶𝑂𝐷 𝑜𝑢𝑡
Eff. COD 𝑥100`%
𝐶𝑂𝐷 𝑖𝑛
removal =
= ((362,75 – 48,35)/362,75) x
100%
= 87%
𝑁𝐻 𝑖𝑛−𝑁𝐻3
Eff. NH3 removal 3 𝑜𝑢𝑡
𝑥100
𝑁𝐻3 𝑖𝑛
=
= ((36,22 – 19,84)/36,22) x 100
= 45% (rendah). Ada masalah di
proses?

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Aspek-aspek O&M (II-b)

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Aspek-aspek O&M(III)

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Aspek-aspek O&M (IV)
• OPEX cost
• Harus ada budget untuk OPEX (telah direncanakan
sebelum IPAL dibangun)
• Spare-parts (Blower: air filter, van belt, Pump: motor, etc.)
• Consumables products (test strip/test kit, chemicals)
• Desludging service
• Overall electricity bill
• Monthly lab test, etc.

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Aspek-aspek O&M (V)
• Keselamatan (Safety)
• Untuk peralatan
• Misal: automatic pressure relieve valve
 pada outlet blower 
menghindari kerusakanpada diffusers
• Temperature sensor pada rotating
equipment
• Untuk Operator
• Tanda-tanda (caution signs) harus
terpampang dengan jelas
• Tangga & hand-rail, alat sampling dll.
• Sistem alarm & emergency button
• PPE (alat pelindung diri)
• Lingkungan sekitar
• Hindari bahan kimia untuk tidak tercecer

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Any
Questions?

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O&M Sistem IPAL& Troubleshooting

Paramater Secondary
Treatment
Pemeliharaan pada Proses Secondary Treatment

Pretreatment  melindungi/memelihara proses di unit secondary

treatment 
Memastikan Biological treatment berjalan secara stabil.
How the pretreatment can protect the Secondary
Treatment?

• Pretreatment menurunkan/
memisahkan sebagian
besar padatan (SS), • Dampak tidak ada pretreatment:
• Turunnya DO level di reaktor (high SS)
colloidal, FOG atau toxic
material. Particulates • Pollutant removal menjadi lambat
(terutama untuk COD partikel/colloid)
COD removal eff.
±60 – 90%. • Scum formation

• Sludge settleability problem (Sludge

L o w effluent quality
bulking)
(keruh)

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Contoh (1) O&M pada unit Pretreatment
(Domestic wastewater)
Less maintained Better maintained

To the
reactor

kiri: influent (high organic kiri: influent (less solids join)

solids) kanan: setelah kanan: setelah secondary
secondary treatment (keruh, treatment (lebih jernih, COD
offset COD) ok)

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Contoh (2) O&M pada unit Pretreatment
(Industrial wastewater)

To be
maintained:
Floated suspended solids
(SS).
Removal ~95-98%
Pemeliharaan pada unit Secondary Treatment
1.Maintain microbial
community

2.Maintain Operational
Parameters
• F/M ratio
• SVI
• HRT
• SRT
• Nutrients
concentration Conventional Activated
sludge
3. Maintain Environmental
Parameters
• DO • Menghindari sludge bulking (sludge mengembang
level dan sulit settle)
• pH, T • Menghindari washed-out bacteria (hilangnya mikro-
organisme
dari reactor)

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1. Menjaga (Maintain) Microbial Community
• Bacteria (paling banyak di AS
system)
• Protozoa
• Amoeba, Flagellates, Free-
swimming ciliates, Crawling
ciliates, Stalked ciliates
Bacteri Protozoa &
• Metazoa (rotifers, a Metazoa
nematodes, water bear,
etc.)
• Filamentous bacteria
• Algae and fungi (jamur)
Filamentous alga
bacteria e

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2. Maintain Operational Parameters – F/M Ratio

 F/M (Food-to-Mass) Ratio

• F o o d  BOD atau COD
• Jumlah Microorganism di reactor

VSS x V-aeration tank
• Optimal range F/M berbeda-beda
di setiap plant
• F/M for BOD removal 0.2 - 1.0 kg
BOD5/kg MLVSS.d

F/M = 0,2 - 0,45 (untuk CAS)

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F/M (Food-to-Mass)
Ratio
Dampak:
Low F/M ratio  Menyebabkan sludge
bulking

Filamentous
bacteria growing
with floc

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• Check your F/M ratio!
• Exercise:
• V aeration = 50 m3
• Q (flow inlet) = 40 m3/d
• Food = BOD5 inlet is 600 ppm = 0,6
kg/m3
• Microorganism = VSS = 2000 ppm = 2
kg/m3
F/M = (Q x [BOD] )/(V x
[MLVSS]) F/M is basically
= (40 x 0,6) /(50 x 2) maintained by adjusting
= 0,24 kg-BOD/kg- MLVSS.d the recirculation ratio
= 0,24 kg/kg.d
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2. Maintain Operational Parameters – SVI(mL/g)

Sludge Volume Index digunakan

untuk mengetahui sludge bulking
atau tidak.
Sample Sludge
• How to calculate the SVI? liquor from level after
• Allow a mixed liquor sample from the aeration reactor 30 min
basin to settle for 30 minutes
• Determine the MLSS (mg/L) from aeration
tank from lab result (the same with TSS)
• SVI < 80 fast settling, excellent
• SVI 80 - good, excellent settling
120 poor settling (bulking
• SVI > 150 sludge)

(untuk CAS biasa dikisaran 100 – 150 mL/g)

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Case study 1: Beverage Industry (WestJava)

Problem:
• SVI = tidak bisa
ditentukan
• Return sludge ke
reaktor tidak rutin
• Settling cukup lama
untuk mencapai
effluent yang jernih

Action
Settled bacteria after 30 (troubleshooting):
minutes (left) and after 24 Increase the RAS flow!
hours (right)

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Casestudy 2: Sludge bulking at Recycling paper
factory – West Java
Liquor from reactor

Problem:
• MLSS = 8020 mg/L= 8 g/L
(lab result)
• Hasil kalkulasi SVI = 400
mL/g (thick sludge),
seharusnya <120 mL/g

•High SS ikut di effluent

Action
Increase the WAS flow
Pengenceran 4x untuk (troubleshooting):
mengetahui actual
After 2 hours settling
SVI
Difficult to observe the sludge
level
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2. Maintain Operational Parameters – SV30
(mL/L)

Quick test: Sludge settleability using SV30 (mL/L)

 2. Maintain Operational Parameters – HRT(hour)
- Hydraulic Retention Time (HRT)  Lamanya waktu
tinggal air limbah untuk kontak dengan microorganism
di dalam reactor 𝑉 (𝑚 3 )
- Dihitung melalui rumus: 𝐻𝑅𝑇(ℎ) = 𝑄 ( 𝑚 3 / ℎ )

- Solution
- Flow harus rata di setiap jam,
caranya: Buffer tank yang
cukup, minimal 60% dari flow
per hari 2
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 2. Maintain Operational Parameters – SRT(day)

Sludge Retention Time (SRT) = Sludge Age

• Lamanya sludge (bakteri) tinggal di reaktor
dan kontak dengan substrate (food
source).

• Contoh untuk conventional activated

sludge plant, SRT sekitar 3 - 15 hari.
Impact:

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Impact: Long SRT (old sludge)
• Rising solid in clarifier • Sludge
clamping

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• Pin-floc/Sludge deformation (long SRT)

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How to calculate SRT
• Calculation example:
• Vaer= 50 m3
• Qi = 40 m3/d
• Qw= 6 m3/d (WAS)
• Qe = 40-6 =34 m3/d
• TSSeff= 20 mg/L
• MLSS= 4000 mg/L = 4 kg/m3 (reactor)
• Konsentrasi WAS=RAS (Xr) = 6000
mg/L = 6
kg/m3

• Sludge di reactor = 50 m3 x 4 kg/m3= Typical SRT CAS 3 to 15 days

200 kg Untuk proses nitrifikasi,
• Sludge dibuang = [(6 m3/d x 6 kg/d)] + diperlukan SRT yang lebih
[(40- lama.
6) m3/d x 0,02 kg/m3]= 36,72 kg/day
• SRT = 200kg/ 36,08 kg/d = 5,5 days 3
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Case study: Paper Recycled Fact. - WestJava
Membangun clarifier baru dgn ukuran 2 kali lebih
besar 
• Previous condition:
• High sludge bed, supernatant (clear
effluent) hanya berjarak 10 cm dari
sludge bed.
• Kualitas effluent mengandung SS yang
tinggi
• PAC is dosed   tidak berhasil
• Calculated SRT  35 days

Action to take (troubleshoot):

Waste more sludge to lower SRT to 10
days (untuk mencapai SVI di dibawah
120 mL/g)

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2. Maintain Operational Parameters – Rasio Nutrients
(COD:N:P)
• carbon 50 %

• Composition • oxygen 22 %

microorganism • nitrogen 12 %

(sludge): • C5H 7NO 2 • hydrogen 9%

• phosphorus 2%
• 80% water / 20% dry
matter • sulphur 1%

• 90% organic / 10% • potassium 1%

inorganic • sodium 1%
• calcium, magnesium, chlorine, iron
• other trace elements
• Favourable nutrients (influent composition)
• COD : N : P + trace-elements
• 100 : 5 : 1 + “vitamin”

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• Domestic wastewater Nutrient level cukup
• Industrial wastewater imbalance nutrient
• Case study: beverage industry – Sample feed (taken from EQ
Tank):

COD : N : P = 100 :
5:1

Correct

composition: 692

mg/L COD

7,0 mg/L P
35mg/L N

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• Impact on nutrients deficiency:
• Bacteria washed-out
• High COD concentration in the effluent
• Bulking sludge

• Action to maintain Nutrient

level (troubleshoot):
• Adding N supply  common source urea
(CH₄N₂O)
• Untuk awal bisa ditambahkan ±10% extra dari ratio.
Note: Penambahan dilakukan di buffer/equalization
tank
• Monitor the formation of nitrate (NO3-N) dan dijaga
untuk tidak lebih dari 5 mg/L
• Pengukuran NO3 bisa langsung menggunakan NO3
strip
• Adding P supply  Phosporic acid (H3PO4)
• Note: hati-hati, overdose bisa menurunkan
alkalinitas (buffering capacity)  pH drop 36
3. Maintain Environmental Parameters – DOlevel
• DO level yang harus di-maintain:
tidak kurang dari 2 mg/L
• Alasan: konsentrasi 2 mg/L bisa menjangkau
bagian tengah dari floc (center of the
biological floc)
• Umumnya: DO level 2-5 mg/L
(bergantung dari polutan yang ingin
dihilangkan: COD saja atau
COD + Nitrogen)
• DO < 2 mg/L  poor settling
 banyak filamentous
bacteria  effluent
keruh
• Diatas 5 mg/L  high
turbidity in the effluent
Source: iwaponline
• Troubleshooting (Bila DO < 2 mg/L)
• Check COD dan/atau Nitogren load (kg-COD/hari atau kg-N/hari)  sesuai design
awal? If ok 
• Check kapasitas blower (kebutuhan O2 per hari  dikonversi ke kebutuhan
udara Nm3/hari) 1 kg-COD ~ 1 kg O2
1 kg-N ~ 4.6 kg O2 (TAN)  untuk proses nitrifikasi
• Rule of Thumb:
• Blower Capacity = [Total O2 need] / [O2 content in air x air density x *SOTE]
*SOTE = Standard Oxygen Transfer Efficiency, typical value for fine bubbles diffuser at 4.5 mOther
submergence
factor need to =
be25% –
considered
• Calculation
35% for more detail calculation:
- Type of wastewater ( α factor),
• Q = 100 m3/day
example: elevation, temperature, pressure
• COD to be removed = 350 mg/L at site.
• N to be removed = 70 mg/L
• O2 needed for COD removal = [100 m3/day x 1 kg-O2 x 350 mg/L] / 1000 = 35 kg O2/day
• O2 needed for N removal = [100 m3/day x 4.6 kg-O2 x 70 mg/L] / 1000 = 32.2 kg O2/day
• Blower capacity = [(35 + 32.2) kg O2/day] /[ 21% x 1.27 kg/m3 x 20% ]= 1260 Nm3/day =
875 LPM
• Diffusers scaling issue

• Check hydraulic flow (untuk sistem continuous disarankan feeding scenario sekurang-
kurangnya di-bagi ke 16-20 jam per hari. Dibutuhkan buffer yang cukup untuk
pembagian feed.
• Check apakah banyak organic particles yang join di inlet. Degradasi partikel COD
membutuhkan DO.

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3. Maintain Environmental Parameters – pH
• Biological p r o c e s s o p t i m u m
pada:
• pH 7.0 untuk COD removal
• 7.0 – 8.0 untuk nitrifikasi (N removal)
• Save range at 6,8 – 8,5
• pH < 6,5 slow removal rate of COD
&N
• Case:
• Jika pH drop dibawah 6.0 tapi
ammonium
• masih melebihi baku mutu.
• Penyebab:
• Turunnya buffering
capacity/alkalinitas dari
limbah/liquor di aeration tank
Troubleshoot:
• Bila ada komponen NO3 di
effluent dalam jumlah yang
relative cukup  consider pre-
denitrification process.
• Denitrification akan
mengembalikan
alkalinitas ke limbah/liquor
s e h i n g g a pH naik (save
aeration too).
• Check kebutuhan external Carbon
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for nitrification
Any
Questions?

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