CALCIUM REMOVAL SYSTEM Pres. (4XD_wcb).ppt

7/29/2019 CALCIUM REMOVAL SYSTEM Pres. (4XD_wcb).ppt

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CALCIUM REMOVAL SYSTEM

(DE- CALCIUM SYSTEM)

PRESENTED BY:

ANGELO MAAMBONG AMISTAD


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DESIGN BASIS

ITEM UNIT VALUE

pH - 6.5 ~ 8.5

TSS ppm 10

Turbidity NTU 5.0

COD ppm 20

T- Alkalinity ppm 50TOC ppm 7.0

Si ppm 10

Na ppm >200

Ca ppm 700

Mg ppm 100

Fe ppm 0.05

Mn ppm 1.0

Cl ppm 20

SO4 ppm 2200

NO3 ppm 1.5

Al ppm 0.2

Ni ppm 0.01

Zn ppm


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PROCESS OVERVIEW

De- Ca

Reaction TankNo. 1

(224TK02)

De- Ca

Reaction TankNo. 2

(224TK03)

De- Ca Thickener(224TH01)

pH Adjust Tank(224TK04)

De- Ca Water Pond(224PD02)

Supernatant De- Ca Water

Na2CO3

CaCO3 (Recycled)

NaOHNaOH

PolyFerric Sulfate

PolymerNaOH H2SO4

CaCO3 (Sludge)


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DE- CA MAIN PROCESS AREA

224PD02224TH01

224TK04 224TK03 224TK02

pH Adjust Tank No. 2 Reaction Tank No. 1 Reaction Tank

De- Ca Water Pond De- Ca Thickener


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MAIN PROCESS DESCRIPTION

* REACTION TANK NO.1 (224TK02) *

Supernatant Water enters this tank Soda Ash (Na2CO3) and Caustic Soda (NaOH) are dosed into

this tank

10% NaOH is used to raise the pH between 10 ~ 11 (AIC-101)

10% Na2CO3 (dosing rate at 4.25 m3/ hr) is used as softener toreplace Ca2+ present in the wastewater

Overflow goes into Reaction Tank No. 2 (224TK03)

Main Chemical Reaction:

CaSO4 + Na2CO3 (slurry) Na2SO4 + CaCO3(s)( Supernatant Water)

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


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MAIN PROCESS DESCRIPTION* REACTION TANK NO. 2 (224TK03) *

Other than the overflow from Reaction Tank No. 1(224TK02), 10% NaOH, 10% Na2CO3 (valve is normallyclosed) and PolyFerric Sulfate (PFS or Fe2(SO4)3) aredosed into this tank.

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

PFS (conc. = 335 mg/L & dosing rate at 1.2L/ min) is

used as coagulant

Overflow goes into the De- Ca Thickener (224TH01)


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MAIN PROCESS DESCRIPTION* DE- CA THICKENER (224TH01)*

Sedimentation and Bridging

Polymer PA331 (3 mg/ L, dosing rate at 8 L/ min) is

used in this unit

Settling sludge, CaCO3 slurry, is pumped out for reuse

or for recirculation back to Reaction Tank No. 1

(224TK02)

Treated water overflows to pH Adjust Tank (224TK04)


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*pH ADJUST TANK (224TK04)*

pH (AIC-103) of treated water is adjusted to 6.5 ~ 8.2

where NaOH and H2SO4 solution are used as adjusting

reagents

H2SO4 is dosed when pH > 8.2 and it is stopped when

pH < 7.7

NaOH is dosed when pH < 6.5 and it is stopped whenpH > 7.0

Treated water overflows to the De- Ca Water Pond

(224PD02)



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* DE- CA WATER POND (224PD02)*

Served as reservoir of De- Ca Water Supply

Softened water

Target Ca conc. 30 ppm



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DE- CA CHEMICALS

A) Sulfuric Acid (H2SO4)

B) Polyferric Sulfate or PFS (Fe2(SO4)3)

C) Caustic Soda (NaOH)

D) Soda Ash (Na2CO3)

E) Polymer (PA-331)


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CHEMICALS PREPARATION & FEEDING CHEMICAL CONSUMPTION

10% H2SO498% H2SO4 = 1,048 kg/ day

Dil. H2SO4 Storage Tank = 5 m3

Dil. H2SO4 Feed Pump = 3 m3/ hr x 15 m

10% NaOH

24% NaOH = 4,400 kg/ day

Dil. NaOH Buffer Tank = 5 m3

Dil. NaOH Feed Pump = 3 m3/ hr x 15 m

Polyferric Sulfate (PFS)

11% as Fe = 1,704 kg/ day

PFS Storage Tank = 2 m3

PFS Feed Pump = 0.8 L/ min x 20 m

Polymer

3 ppm x 200 m3

/ hr = 600 g/ hr600/ 0.1% = 600 L/ hr, 14400 L/ day

Polymer Tank = 5 m3 x 2 sets

Polymer Dosing Pump = 8 L/ min x 20 m

Na2CO3

10% Na2CO3 = 107 ton/ day

Slurry Tank = 30 m3 x 2 sets

Slurry Feed Pump = 4.2 m3/ hr x 15 m


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CHEMICALS PREPARATION & FEEDING

CHEMICALS PREPARATION

A) 10% NaOH

Dilution Tank (224TK08)

It has a capacity of 1.0 m3 where dilution of 24% NaOH to 10%concentration takes place.

Dilution Procedure:1) Fill the tank with the required amount of raw water by opening valve

224DIV043. Auto filling starts at LL level (7%) and stops at M2 level (68%).

2) Fill with required amount of 24% NaOH into the tank by opening valve224DIV039. Auto filling starts at M2 level (68%) and stops at H level(86%).

3) Agitator (224AG08) auto start to stir and stop after certain time.

Diluted NaOH Buffer Tank (224TK09)

The tank has a capacity of 5.0 m3 to handle 10% NaOH solution supplied

from NaOH Dilution Tank.


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B) 10% H2SO4

Dilution Tank (224TK10)

It has a capacity of 2.0 m3 where dilution of 98% H2SO4 to 10% concentrationtakes place.

Dilution Procedure:

1) Fill the tank with the required amount of raw water by opening valve 224DIV084.

Auto filling starts at LL level (23%) and stops at M2 level (88%).

2) Fill required amount of 98% H2SO4 into the tank by opening valve 224DIV081.

Auto filling starts at M2 level (88%) and stops at H level (94%).

3) Agitator (224AG10) auto start to stir and stop after certain time.

Diluted H2SO4 Storage Tank (224TK11)It has a capacity of 5.0 m3 to contain the 10% H2SO4 solution supplied fromDilution Tank.



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C) 10% Na2CO3

Mixing Tank (224TK05)

This tank has a capacity of 30 m3 where dissolution of powdered Na2CO3 to 10%

concentration takes place.

Dissolution Procedure:

1) Fill the tank with the required amount of raw water by opening VALVE V-196.

Auto filling starts at L level (7%) and stops at H level (91%).

2) Run Agitator (224AG05) to stir when level reaches 50%.

3) Fill required amount of Na2CO3 when agitator is running already.

Slurry Tank (224TK06/ 224TK07)Each tank has a capacity of 30 m3 and serve as storagetank for the 10% Na2CO3

slurry prior for feeding to Reaction Tank No. 1 (224TK02).



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DE- CA DCS SCREEN

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


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DE- CA LCP SCREEN

De- Ca operation is controlled via LCP.


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DE- CA LCP SCREEN


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DE- CA LCP SCREEN


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LOCAL CONTROL PANELS

De- Ca System Control Panel

Polymer Local Panel

(LCP-1)

Na2CO3 Mixing

Local Panel (LCP-2)

Door 1 Door 2 Door 3 Door 4


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MAIN PROCESS CONTROL SWITCH

AGITATORS & REDUCTION GEARS


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CONTROL VALVES & PUMPS

MAIN PROCESS CONTROL SWITCH


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NaOH DILUTION CONTROL VALVES, AGITATOR & PUMPS

DE- CA CHEMICALS CONTROL SWITCH


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H2SO4 DILUTION CONTROL VALVES, AGITATOR & PUMPS



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POLYFERRIC SULFATE OPERATION CONTROL VALVES & PUMPS


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SODA ASH OPERATION CONTROL VALVES, AGITATOR & PUMPS



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POLYMER OPERATION CONTROL VALVES, AGITATORS & PUMPS

GENERAL STEP BY STEP PROCEDURE IN LCP


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GENERAL STEP-BY- STEP PROCEDURE IN LCP

OPERATION

1) Switch ON Main Incoming Power. 2) Switch ON circuit breakers for LCP

Display Monitor and other breakers for

field instruments/ sensors.

LCP DisplayMonitor Circuit

BreakersField Sensor

Circuit Breakers

3) Switch ON circuit breakers of the specific

equipment or valve for operation.


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GENERAL STEP-BY- STEP PROCEDURE IN LCP

OPERATION

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

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

OPERATIONNORMAL OPERATION MODE

AGITATORS PUMPS CONTROL VALVES REDUCTION GEARS

A) De- Ca Main Process RUN AUTO AUTO RUN

B) Na2CO3 Operation RUN RUN (Transfer) AUTO -

AUTO (Feed)

C) NaOH Operation AUTO AUTO AUTO -

D) H2SO4 Operation AUTO AUTO AUTO -

E) PFS Operation - RUN (Loading) AUTO -

AUTO (Feed)

G) Polymer Operation (w/START button)

AUTO AUTO AUTO -


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OPERATING PROCEDURE

AGITATORS Selection switch to AUTO mode

- NaOH Dilution Tank Agitator (224AG08)

- H2SO4 Dilution Tank Agitator (224AG10)

- No. 1 Polymer Tank Agitator (224AG12)

- No. 2 Polymer Tank Agitator (224AG13)

Selection switch to RUN mode at start up

- No. 1 Reaction Tank Agitator (224AG02)

- No. 2 Reaction Tank Agitator (224AG03)

- Reduction Gear for Rake (224RG01)

- Reduction Gear for Coagulator A/B/C (224RG02A/B/C)

- pH Adjust Tank Agitator (224AG04)

- Na2CO3 Mixing Tank Agitator (224AG05)

Thickener (224TH01)


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PUMPS

Selection switch to AUTO mode

- De- Ca Water Pump A/B (224PU04A/B)

- CaCO3 Slurry Pump A/B (224PU06A/B)

- Diluted NaOH Transfer Pump A/B (224PU09A/B)

-

Diluted NaOH Feed Pump A/B (224PU10A/B)- Diluted H2SO4 Transfer Pump A/B (224PU11A/B)

- Diluted H2SO4 Feed Pump A/B (224PU12A/B)

- Na2CO3 Slurry Feed Pump A/B (224PU08A/B)

- Polymer Feed Pump A/B (224PU13A/B)

- Polyferric Sulfate (PFS) Feed Pump A/B (224PU14A/B)- De- Ca Area Sump Pump (224PU15)

Selection switch to RUN mode

- PolyFerric Sulfate (PFS) Loading Pump (224PU16)

OPERATING PROCEDURE


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TANKS AUTOMATIC VALVES

Switch auto valves to AUTO mode

NaOH

Dilution Tank Inlet Valve (XV-107)

No. 1 Reaction Tank Dosing Valves (XV-101 and XV-102)

No. 2 Reaction Tank Dosing Valves (XV-103 and XV-104)

pH Adjust Tank Dosing Valve (XV-106)

H2SO4 Dilution Tank Inlet Valve (XV-109)

pH Adjust Tank Dosing Valve (XV-105)

Raw Water Inlet Valve to NaOH Dilution Tank (XV-108)

Inlet Valve to H2SO4 Dilution Tank (XV-110)

OPERATING PROCEDURE

T


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pH METERS & OTHER INSTRUMENTS

pH

- Reaction Tank No. 1 (AIC-101= 10 ~ 11)- Reaction Tank No.2 (AIC-102= 10 ~ 11)

- pH Adjust Tank (AIC-103= 6.5 ~ 8.2)

Density

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

Flow

- FIQ-101

- FIQ-102- FI-103

- FI-104

Note: Monitor all level gauges/ sensors, pressure gauges and instrument air

supply.

OPERATING PROCEDURE

T


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DESIGN STREAMS FLOW RATE FOR PUMPS

A) De- Ca Water Pump (224PU04A/B) 200 m3/ hr

B) CaCO3 Slurry Pump (224PU06A/B) 45 m3/ hr

C) Dil. NaOH Transfer Pump (224PU09A/B) 3 m3/ hr

D) Dil. NaOH Feed Pump (224PU10A/B) 3 m3

/hrE) Dil. H2SO4 Transfer Pump (224PU11A/B) 3 m

3/ hr

F) Dil. H2SO4 Feed Pump (224PU12A/B) 3 m3/ hr

G) Na2CO3 Slurry Feed Pump (224PU08A/B) 6 m3/ hr

H) Polymer Feed Pump (224PU13A/B) 8 L/ minI) Polyferric Sulfate (PFS) Feed Pump (224PU14A/B) 1.2 L/ min

J) De- Ca Area Sump Pump (224PU15) 18 m3/ hr

OPERATING PROCEDURE

SUMMARY ON CHEMICAL REQUIREMENTS PER


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Chemicals

Optimum Tanks

Capacity(m3)

Required Weight/ Volume

Start- Up Operation Normal Operation

10% NaOH 1.02

Raw Water 647 L 546 L

24% NaOH 373 L 314 L

10% H2SO4 2.10Raw Water 1,976 L 1,411 L

98% H2SO4 124 L 89 L

10% Na2CO3 29.90

Raw Water 29.02 m3 26.4 m3

100% Na2CO3 3,289 kg (3.3 tons) 2,992 kg (3.0 tons)

0.1% Polymer 4.40 (per tank)

Raw Water 4,400 L 3,800 L

Polymer (PA-331) 4.49 kg 3.88 kg

Polyferric Sulfate (PFS) 2.00 -same- 1.6 m3

SUMMARY ON CHEMICAL REQUIREMENTS PER

DISSOLUTION/ DILUTION

ALARMS & COUNTERMEASURES


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ALARMS & COUNTERMEASURESGENERAL NATURE

OF ALARM

EQUIPMENT/

UNIT INVOLVED

CAUSE AUTOMATIC

RESPONSE

COUNTERMEASURES

1) TRIP

1) Tank Agitator

Overload

Not OperateCorrectly

Reset Breaker

2) Reduction Gear Stops operating Reset Breaker

3) Pump Stops operating

Check setting current againstrating current of motor andadjust main circuit breaker.

Check motor and mechanicalrotation of driving equipment.

2) HIGH LEVEL

1) De- Ca Water

Pond

The incoming flow

rate exceed designcapacity or;

Pump start

Check and control the

incoming flow rate.

2) De- Ca Area Sump Flow rate of pump(transfer or feed) isbelow the designcapacity.

Adjust the flow rate.

Stop Loading pump (for PFS

case only)3) Chemical Tanks

3) INSTRUMENT AIR

PRESSURE LOW

De- Ca Pneumatic

Operated valves.

No air supplied. Valves stop

functioning.

Check for air leakage/ supply.

4) HIGH pH

1) Rxn Tank No. 1 Excess dosage ofNaOH or Na2CO3.

-

Adjust the chemical dosagethru the needle valve at thedosage point.

2) Rxn Tank No. 2 Excess dosage ofNaOH.

-

3)pH Adjust Tank Insufficient dosageof H

2

SO4

soln. orexcess dosage ofNaOH.

-



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GENERAL NATUREOF ALARM

EQUIPMENT/UNIT INVOLVED

CAUSE AUTOMATICRESPONSE

COUNTERMEASURES

5) LOW pH

1) Rxn. Tank No. 1 Insufficient dosage ofNaOH or Na2CO3.

-

Adjust the chemical dosagethru the needle valve at thedosage point.

2) Rxn. Tank No. 2 Insufficient dosage ofNaOH solution.

-

3) pH Adjust Tank Insufficient dosage ofNaOH or excessdosage of H2SO4.

-

6) HIGH DENSITY

Na2CO3 Mixing

Tank

Insufficient dosage ofraw water or excess

dosage of Na2CO3.

A) Reduce the charging orloading of Na2CO3.

B) Increase the raw water flowrate by opening XV-111.

7) LOW DENSITY

Na2CO3 Mixing

Tank

Insufficient dosage ofNa2CO3 or excessdosage of raw water.

A) Increase the charging orloading of Na2CO3.

B) Decrease the raw water flowrate by closing XV-111.

8) OVER TORQUE Reduction Gear for

Rake

Overload - Reset breaker

9) TORQUE HIGH Too thick or too muchof sludge.

- Discharge the sludge.

10) EMERGENCY

STOPLCP EmergencyStop Button

Emergency Stopbutton was pushed.

Stop Operation Reset the button.

11) EARTH LEAKAGE LCP Wire not properlyconnected.

- Reconnect the wire and resetELCB.

12) PUMP DRY Pumps in De- CaArea

Shortage of water orcontent.

Equipment stopsoperating.

Fill up the tank.



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ENVIRONMENTAL BENEFITS

Reference

Timeframe

Wastewater/ Supernatant Circulation & Discharge

Tot. Discharge

from Tailings Dam(m3)

Recycle to Plant

(m3

)

Discharge to Pier

(m3

)

% Discharge

to Pier

TSS DISCHARGE

LOAD (kg)

Jan- Dec 2007 1,323,989.3 411,589.7 906,333.4 68.45 9, 063.3

Jan- Sep 2008 1,148,366.7 472,093.2 673,162.0 58.62 6, 731.6

Jan- Dec 2008 1,500,000.0

(Estimated)

600,000.0

(Estimated)

900,000.0

(Estimated)

60.00 9, 000.0

Jan- Dec 2009(w/ CBNH-2)

3,000,000.0

(Estimated)

2,784,000.0 216,000.0 7.2 2, 160.0

ADDITIONAL DATA: NO. OF OPERATING DAYS IN A YEAR = 315 DAYS

AVERAGE TSS DISCHARGE TO PIER = 10 ppm

% REDUCTION IN DISCHARGE TO PIER = 52.8 %

% REDUCTION IN TSS DISCHARGE LOAD = 76.0 %

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

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

CALCIUM REMOVAL SYSTEM Pres. (4XD_wcb).ppt

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