MISR SPINNING & WEAVING CO.

(Mehalla Kubra)
INDUSTRIAL WASTE WATER TREATMENT
PLANT
CAPACITY: 50,000 m³/day-
PRETREATMENT
40,000 m3/day – SECONDARY & POST
TREATMENT
DESIGN CRITERIA & PROCESS
DESCREPTION
• Characteristics of waste water of Misr spinning and weaving company.

• Influent wastewater characteristics:

• Flow : 2.200 m3/h 50.000 m3/d

• COD : 530 mg/l Load 26.500 kg/d

• BOD : 242 mg/l Load 12.100 kg/day

• BOD/COD > 0.46

• TSS : 384 mg/l Load 19,200 kg/d

• pH : 9 – 11

• Color : 200 Units

 GENERAL OVERVIEW OF THE PLANT
Wa ste Wa te r

PART A PARTB
PART C
PRETREATMENT BIOLOGICAL REACTOR
SECONDARY POST TREATMENT
-Sc re e ning PRETREATED Ae ra tio n – TREATED Chlo rina tio n fo r
- Oil & g re a se WATER se d im e nta tio n WATER d isinfe c tio ns &
skim m ing Ad ditio n o f po wde re d Oxid a tio n o f
-Pum ping Ac tiva te d Ca rb o n a nd COD/ Co lo r re m o va l
ACTIVATED
-Co nd itio ning Bio -So lid s Wa sting sa nd Anthra c ite
-Adso rp tio n o n SLUDGE Nutrie nt re m o va l (N & P) filtra tio n
Bio m a ss a nd Pa c
- Ne utra liza tio n EFFLUENT TO BE DISCHARG
-Co a g ula tio n
EXCESS BIOLOGICAL SLUDE
-Flo c c ula tio n
- Se d ime nta tio n
PARTD
PRIMARY
WASTE SLUDGE TREATMENT
SLUDGE
Sludg e
Sta b iliza tio n/
Thic ke ning / De wa te ring

DEWATERED SLUDGE FOR DISPOSAL

AL Mehalla
project is an industrial wastewater treatment
plant (Textile Waste Water) with a capacity of 50.000 m3/day.
We have split up the project in 4 parts:

• Part A Pretreatment

• Part B Bioreactors aerobic LUCAS System

• Part C Chlorination & Filtration.

• Part D Sludge treatment.

Part A

The Pretreatment consists of:

• Oil & Grease Skimming

• Manual Coarse Screening

• Mechanical Fine Screening

• Conditioning and adsorption on activated sludge and PAC

• pH controlling system.

• Coagulation and flocculation

• Pre-settling.
Pretreatment Is physicochemical treatment to:

• Equalization & discoloration to the WW by retained biosludge in Buffering

tank by Mixing & aeration in aerobic condition.

• Neutralization to adjust pH of the influent WW. by add acid (mainly)

Due to the WW have high alkaline pH range 9 -11with facilitation of base
adding in case of WW. pH shall be less than 7.00

• Coagulation by coagulant ( Alum or Ferric chloride) to enlarge the size

suspended solids

• Flocculation by flocculent ( Anionic polymer ) to increase the settiability of

the suspended solids.

• Sedimentation of suspended solids including biosolids and suspended

solids in settlement tanks.
This drawing is the confidential property of WATERLEAU GLOBAL WATER TECHNOLOGY NV. Informat ion and know how hereon are confident ia l and may not be us ed,
re produced or revelealed t o ot hers except in accord with cont ract or other written permis sions of WATERLEAU GLOBAL WATER TECHNOLOGY NV.
Any reproduct ions in whole or in part including s hop drawings s hall bea r or refe r t o this stamp.
Estimation of Removal efficiency after Pre-treatment
by Physicochemical method :

• COD : 400 mg/l removal % 25%

• BOD : 200mg/l removal % 20%

• TSS : 200 mg/l removal % 50 %

• Color : 40 unit removal % 80 %

• pH : 7–9
Part B

Biological Reactors Two Lane LUCAS System

• The biological reactor is divided into 2 lanes each lane consists of 3 basins.
• All basins are equipped with surface aerators to provide necessary oxygen for
treatment process.
• All basins are equipped with submersible mixers to assure good mixing of the
water with activated sludge and to prevent dead zones in the basins .
• Water levels are controlled by Level Switches to prevent overflow of the basins
• Oxygen concentration in the water is controlled by Oxygen Meters to reserve
always a certain amount of oxygen in the water.
• At any time oxygen concentration is higher than a certain point surface
aerators will stop which save energy. At that time mixers are still working to
assure mixing of the water with activated sludge and keep the water in a
suspension phase all the time
• Basins are also equipped with submersible pumps to transfer excess sludge to
buffer tank and for sludge treatment.( part D )
 LUCAS® Leuven University Cyclic Activated sludge
LUCAS® Hydraulic scheme
Influent Influent

Effluent Effluent
Aeration/sedimentation Aeration Aeration/sedimentation

Air Blowers

Excess Sludge

- The 3 units are hydraulically connected

- Thus hydraulic connections combine the individual units into a single tank
 LUCAS® Cyclic
Influent
operation
aeration aeration sedimentation Effluent

Mainphase 1

Influent

Effluent
sedimentation aeration aeration
Mainphase 2
Bio-solids production (per lane)

• Excess biosolids production 2.000 kg MLSS/day

• Excess biosolids flow rate 200 m³/d

• Waste Time 8 hrs

• Excess sludge flow rate 25 m³/hr

SLUDGE WASTING

• The excess biosolids of the LUCAS reactor (of the 2

lanes) are pumped by 4 submersible pumps (two pumps
in each lane) with a capacity of 25 m3/h (each) back to
the Pre Treatment (PART A) and / or to Sludge
Treatment (Part D) .
• The excess biosolids to (Part A )will act as an
adsorbents for color reagents and other organics with
the PAC.

• The total sludge production will be: 13, 600 kg DS/day.

Rinsing phase:

• Before a compartment becomes a settling compartment and effluent

is discharged through its launders, a short rinsing phase is inserted
to rinse the launders. This rinsing water, which contains suspended
solids, sludge, flows by gravity to the rinsing pit.

• Supernatant from the sludge thickeners and filtrate of the sludge

dewatering are also flowing to the rinse pit.

• The rinsing pit serves thus as a storage tank for different internal
waters whose quality is not good enough to send them immediately
to the effluent.and it retrun back to biological reactors.
Characteristics of Treated Water after LUCAS aeration system
( Part B )
• Flow : 1.666 m3/h 40.000 m3/d

• COD : <100 mg/l

• BOD : <50 mg/l

• TSS : <50 mg/l

• pH : 7–9

• Color : <20 Units

(Part C)

POST TREATMENT
Chlorination & Gravity sand filtration.

• To get an extra pure treated water for reuses as

irrigations purposes. The effluent flows by gravity from
the sedimentation compartment of the LUCAS system to
the Chlorine Contact Tank for disinfection and reduction
of total coliform count to the allowable regulation low.

• The disinfected effluent then flows into the influent

filtration tank and will be pumped to filtration units.
This drawing is t he confidential pr opert y of WATERLEAU GLOBAL WATER TECHNOLOGY NV. Information and know how hereon are confidential and may not be used,
reproduced or revelealed t o ot hers exce pt in accord wit h cont ract or other writt en permissions of WATERLEAU GLOBAL WATER TECHNOLOGY NV.
Any reproduct ions in whole or in part including shop drawings shall bear or ref er t o this st amp.
Characteristics of final effluent treated water

After Chlorination & filtration (Part C )

• Flow : 40.000 m3/day.

• COD : 80 mg/l

• BOD : < 30 mg/l

• TSS : < 30 mg/l

• pH : 7–9

• Color : free of color

• Total coliform : < 5000 CFU/ml.

(Part D)

SLUDGE TREATMENT

The sludge treatment systems is consists of 3 stages :

• 1 -Sludge stabilization.

• 2 -Sludge thickening.

• 3 -Sludge dewatering.
• Excess sludge from the biological tanks, in function of
the cyclic operation and in function of the sludge
growth in the package plant to The buffer tank where
we use the sludge and its content of activated carbon
PAC in the process of discoloration of incoming waste
water and then all the sludge including biological
sludge produces from the reactors, and the sludge
produced from the coagulation and flocculation
process which removes about 50-75% of suspended
solids in the sedimentation basins settled in both tanks
and pumped to the sludge stabilization tank .
sludge stabilization:

• The stabilization tank is designed to provide an additional aerobic

sludge age – and thus higher sludge mineralization. The aerobic
digesters are operated with intermittent aeration to allow for
simultaneous nitrification and denitrification – thereby ensuring
alkalinity recovery and preservation – and to prevent anaerobic
conditions that could release back the accumulated phosphorus.

• The digester tank is intermittently aerated and mixing with a surface

aerators & submersible mixers .This ensures excellent suspending
and homogenization and at the same time sludge aeration is done
at high efficiency. And by sludge stabilization the dry solids content
are reduce by 20%

• Sludge concentration in stabilization tank 10-15 gm/l

sludge thickening

• The feed sludge from stabilization tank. is allowed to settle

and compact, by thickening process being enhanced by a
slow turning rake mechanism with bottom scrapers. The
thickened sludge is withdrawn from the bottom of the tank
at 3% as DS content. The supernatant water is returned to
the rinse pit of the biological treatment

• The thickened sludge will be pumped to the 2 new

dewatering filter belt
sludge dewatering

• The thickened sludge from both sludge thickeners. is

allowed to mixed with cationic polymer to enhance the
sludge dewatering by two filter belt press units to
produce dewatering sludge with 15-20% DS.