PTD TSR REVIEW
PT. CHANDRA ASRI PETROCHEMICAL, Tbk
Jl. Raya Anyer Km. 123 Ciwandan , Cilegon.
Banten 42447, Indonesia
TSR Title : WWT Effluent Re-use/Water reclamation project
TSR No. : TSR-452-20-006
Plant/Area : Utility/Waste water Treatment Plant
1. BACKGROUND
In this moment the all of the waste water treatment effluent are safely discharged to sea since the
specification is already comply with government regulation. Regarding the government regulation,
there are annual ward which called PROPER Award that accredited the company about how to treat
waste water system and water. The high score of PROPER award is awarded to company that can
reduce waste water that being discharged and also utilize re-use water system.
UTD team see this opportunity to re-use the WWT effluent to be more usable water. The expectation
of this implementation of Re-using water is processing the effluent of WWT to usable water with
similar specification of treated water. By applying this water re-use application, the waste water
discharge will be reduced, thus this improvement will support company to achieve the highest Gold
PROPER Award.
2. PURPOSE
To conduct the study for WWT effluent Re-use by Utilize filtration system to produce treated water
level quality.
3. OBJECTIVE
- Improve WWT system thus to can support Company to Achieve GOLD PROPER award
- Re-use water WWT effluent to treated water
- Reduce plant water consumption
4. PROCESS REVIEW
CAP is seeking studies to reduce wastewater discharged into the sea by recovering treated wastewater
from outlets to be converted into raw water/fresh water.
A. Basic Design wastewater re-use/reclamation
Basic design for wastewater reclamation project consist of the design quality effluent WWT or feed
waste water reuse, the basic design flow water reclaim (make-up fire water) and the quality of raw
water CAP.
The following table shows feed quality for water reclamation:
Table 1. Waste water effluent parameter and condition
TSR No : TSR-452-20-010 Prepared by : Elysa Setyo P. Signed:
Equipment : Tap Water System Checked by : G. Kunmartanto Signed:
Plant / Area : Water Treatment/WT Approved by : G. Kunmartanto Signed:
Page 1 of 8
PTD TSR REVIEW
PT. CHANDRA ASRI PETROCHEMICAL, Tbk
Jl. Raya Anyer Km. 123 Ciwandan , Cilegon.
Banten 42447, Indonesia
Currently all parameter above are monitored. But we not monitoring regarding parameter TDS (Total
dissolved solid) cause this parameter due to not include in government regulation. However, based
on historical data effluent of WWT at IH-7009 (final check basin), for TDS quality reaches > 2000
ppm. If we are going to reclaim water as process water then TDS might be a concern. The following
is the TDS data on IH-7009 that has been analyzed:
Table 2. Historical data TDS quality at IH-7009
We expect that the quality of water reclaim is close to raw water as feed process. Below are raw water
specification based on BEP ECCX (Basic Engineering Design Data) on 2015
Table 3. CAP’s raw water specification
Team agreed for initial project the proposed of reclaim water is only to be used as make-up fire-water
to replace raw water from KTI. The flow rate required based on graphic below is average 12 ton/h.
However, the system reclaim water is designed for reclaim 70 ton/h, so that beside as make-up fire water,
it expected reclaim water can integrating with current "Water Treatment Plant" as feed process, but the
quality must be concern especially for TDS contain need to be removed.
TSR No : TSR-452-20-010 Prepared by : Elysa Setyo P. Signed:
Equipment : Tap Water System Checked by : G. Kunmartanto Signed:
Plant / Area : Water Treatment/WT Approved by : G. Kunmartanto Signed:
Page 2 of 8
PTD TSR REVIEW
PT. CHANDRA ASRI PETROCHEMICAL, Tbk
Jl. Raya Anyer Km. 123 Ciwandan , Cilegon.
Banten 42447, Indonesia
The following table shows requirement make-up fire water:
60 KTI to Fire Water (Ton/Hours)
50
40
30
20
10
0
1-Jan-2021 21-Jan-2021 10-Feb-2021 2-Mar-2021 22-Mar-2021 11-Apr-2021 1-May-2021 21-May-2021 10-Jun-2021 30-Jun-2021
Graphic 1. Data fire water make-up
B. Basis Concept Wastewater Reclamation
Currently, for the initial study, the team agrees that the design of the reclaim water concept is only
proposed to be used as make-up fire-water to replace raw water from KTI. Which has a low risk and
does not directly impact the plant process.
The concept of reclaimed water is use filtration system with size 2.8m L x 1.52m W x 1.55m H.
A tertiary filtration system will be provided to aide in irrigation/reuse/reclamation effluent. Backwash
will be returned to inlet of biological system. Filter effluent shall be sent to Sand Filter (“SF”) and
Carbon Filter (“CF”) for final polishing. The system will be supplied with standalone 304SS tank
option. The filtration system package is proposed technology from SSI (Stamford Scientific
International, Inc.).
Simplified Process Flow Diagram (PFD) of Reclaim Water from effluent WWTP are follow:
Figure 2. PFD reclaim water from WWTP
TSR No : TSR-452-20-010 Prepared by : Elysa Setyo P. Signed:
Equipment : Tap Water System Checked by : G. Kunmartanto Signed:
Plant / Area : Water Treatment/WT Approved by : G. Kunmartanto Signed:
Page 3 of 8
PTD TSR REVIEW
PT. CHANDRA ASRI PETROCHEMICAL, Tbk
Jl. Raya Anyer Km. 123 Ciwandan , Cilegon.
Banten 42447, Indonesia
Below is Filtration system package proposed by SSI:
Figure 3. Filtration system package
B.1 Filtration system package
The based design on receiving secondary clarifier effluent (ie biological systems) as well as expected
hard water sources. The nominal filtration rating is 10 um (10 micron). It typically produces TSS < 5
ppm and NTU < 5. It is typically rated for > 95% removal efficiency for solids larger than 10 micron.
TSR No : TSR-452-20-010 Prepared by : Elysa Setyo P. Signed:
Equipment : Tap Water System Checked by : G. Kunmartanto Signed:
Plant / Area : Water Treatment/WT Approved by : G. Kunmartanto Signed:
Page 4 of 8
PTD TSR REVIEW
PT. CHANDRA ASRI PETROCHEMICAL, Tbk
Jl. Raya Anyer Km. 123 Ciwandan , Cilegon.
Banten 42447, Indonesia
- The quality parameters of water reclaim that guaranteed are TSS < 10 ppm (before sand and carbon
filter). NTU < 10 (before sand and carbon filter). Organic matter < 5 ppm (before sand and carbon).
Trace metals should not be issue and can be treated chemically if become nuisance level.
- The specification quality of the inlet of filtration package is the inlet quality to filter shall be the
MBBR/Clarifier effluent discharge as previously identified (BOD < 50, COD < 100, TSS < 100, etc.).
- The operating condition of the filtration are 70 m3/hour design flow rate. The filter operates by
gravity. Typically only 1-2 feet of hydraulic head are required, so this is low pressure gravity based
system. Temperatures may range from 4C to 40C.
- Filter effluent shall be sent to Sand Filter (“SF”) and Carbon Filter (“CF”) for final polishing, by
using 10um unit, it offloading TSS to sand and carbon units. Sand and carbon will capture finite
organics, metals and solids that remain to produce excellent effluent.
B.2 Limitation product water reclaim
Reclaim water have concern regarding parameter TDS (Total dissolved solid). Currently CAP not
monitoring this parameter due to not include in government regulation. However, based on historical
data effluent of WWT at IH-7009 (final check basin), for TDS quality reaches > 2000 ppm.
If CAP have plan to going to reclaim water then TDS might be a concern. Because CAP use carbon
steel material in the fire water distribution piping and tanks.
Currently the use of fire water is may not only for emergencies, it is sometimes used for cleaning
equipment and there may be leaks in the pipes due to corrosion. Therefore, the jockey pump will
continue to run to maintain pressure and flow rate in the piping system.
B.3 Cons of Filtration system
- This Filtration System proposed does not consider removal TDS contain in wastewater reuse, so if
fire water is only used in case of emergency, then piping will not scale unless liquid is constantly
pumped through the piping network. To ensure reliable removal of TDS we would have to upgrade
to RO system.
- Removal TDS for fire water purposes may not be required, since EPA and many other European
governing bodies do not limit TDS for reuse (unless it is drinking water). Many states in U.S operating
with TDS 1500-2000ppm for reuse. However carrying high chlorides or dissolved metals will cause
piping and tanks to prematurely wear.
- There are no single point references for fire water quality specifications. EPA does not have
restrictions on TDS for irrigation and industrial reuse. The water will be safe to use in fire, but will
impact mechanical properties and life of your tank and piping. A lot of system use ground water that
has been minimally filtered and disinfected. Keep in mind that USA EPA and Canada define max
TDS for drinking water ~500 ppm. Most countries state 1200 ppm TDS is the absolute maximum for
drinking water.
- If TDS must be removed, another option is blending. Can purchase a small RO unit and recycle ~20%
of the water and blend with discharge from the SF/AC filtration process. This will reduce the total
mass loading TDS/Conductivity that goes to your existing fire water tank.
- Higher TDS will likely the physical/mechanical equipment over time and would likely cause
to replace piping frequently if not dealt with. TDS may also impact the efficiency of salt
scrubber or demineralization of resin properties. If wastewater from WWTP is only used for
TSR No : TSR-452-20-010 Prepared by : Elysa Setyo P. Signed:
Equipment : Tap Water System Checked by : G. Kunmartanto Signed:
Plant / Area : Water Treatment/WT Approved by : G. Kunmartanto Signed:
Page 5 of 8
PTD TSR REVIEW
PT. CHANDRA ASRI PETROCHEMICAL, Tbk
Jl. Raya Anyer Km. 123 Ciwandan , Cilegon.
Banten 42447, Indonesia
Fire, then is acceptable. However if are entertaining option of using in production water, then
it will require additional treatment such as RO.
B.4 Consideration for optional water reclaim as raw water
Quality water for process have standard control limit and should fulfilled (refers to table 3.),
so by using only filtration system still have problem to reduced TDS content. Below are
concern and notes regarding water reclaim:
- TDS cause damage to pipes and tanks with material carbon steel such as corrosion or fouling,
however it will depend on the conductivity level but generally the conductivity will have positive
correlation with TDS (ie if TDS is high, conductivity is high). If the conductivity is high, yes it may
impact carbon steel tank.
- Please note there are only a few reliable method to remove TDS from wastewater: Reverse Osmosis,
Deionization, Ion exchange
- RO is most reliable but highest CAPEX cost (up to 98% effective in most case). Ion Exchange is
slightly lower cost, but carries high ongoing chemical cost. RO would ensure TDS is removed but
requires special disposal of backwash. Note that Nanofiltration is only about 70% effective and
depends on the molecular weight of the TDS solids, but if only require small % removal,
Nanofiltration may work (requires test). The reject from RO is hazardous and requires further
treatment.
- The filter water from reclaim water can be used as process water not only firefighting however it
would not be suitable for long-term use in manufacturing process due to TDS levels. If desire to use
in manufacturing, then RO would be required.
5. REQUIRED MODIFICATION
a) Draft estimation required modification are summarize in below table;
1) Additional Piping System and its accessories (see attachment P&ID)
No Description P&ID No. Tag Number Size Rating Length, m
1 Feed Inlet filtration 1350-00-A211-01 6”WW-XXX-A11L 6” 150# 4
2 Outlet Filtration 1350-00-A211-01 6”WW-XXX-A11L 6“ 150# 4
3 Backwash line E-U23C-0 2”WW-XXX-A11L 2” 150# 30
VD-00-PKG-PID-
4 Outlet FD-7502A/B 6”WW-XXX-A11AU 6” 150# 30
AXCQ001-0002
Outlet New basin to VD-00-PKG-PID-
5 6”WW-XXX-A11AU 6” 150# 2
New pump AXCQ001-0002
VD-00-PKG-PID-
6 Outlet New pump 6”WW-XXX-A11AU 6” 150# 250
AXCQ001-0002
7 New Fire water pipe E-018B-3 4”WW-XXX-A11A 4” 150# 300
2) Additional Filtration system
No Description Dimension Qty Weight
1 Filtration System Package 2.8m L x 1.52m W x 1.55m H 1 < 1,000 kgs
TSR No : TSR-452-20-010 Prepared by : Elysa Setyo P. Signed:
Equipment : Tap Water System Checked by : G. Kunmartanto Signed:
Plant / Area : Water Treatment/WT Approved by : G. Kunmartanto Signed:
Page 6 of 8
PTD TSR REVIEW
PT. CHANDRA ASRI PETROCHEMICAL, Tbk
Jl. Raya Anyer Km. 123 Ciwandan , Cilegon.
Banten 42447, Indonesia
3) Additional Accessories
No Description Qty Size
1 Butterfly valve 1 8”
2 Butterfly valve 4 6”
3 Gate Valve 1 4”
4 Butterfly valve 1 3”
5 Diaphragm valve 1 2”
6 Butterfly valve 1 8”
7 Butterfly valve 4 6”
4) Additional Centrifugal Pump
Suction Press, Discharge
No Description Qty Flow, m3/h Total head, m Power, kW
kg/cm2 Press, kg/cm2
1 Pump 1 70 0.1 2.6 26 9.72
5) Additional Instrumentation
No Description Qty Specification
1 Pressure gauge (PG) 1 unit Range : 0-5 Kg/cm2
2 Level Indicator 1 package -
6) Additional New basin
No Description Qty Dimension Capacity( NET)
1 New basin 1 unit 3800x2900x4800 mm 34 m3
b) Consideration Modification required
During normal operation, the treated water flows directly by gravity from the overflow of the
Filtered Water Pit (IH-7508) to the final check basin, without passing through the Activated
Carbon Filters; but in case COD analyzer detect high COD content on the filtered water going to
the Final Check Basin, the operator has to send by AC Filter Feed and Backwash Pump (GA-
7511A/B) a part of the flow rate (max. 50 m3/h) to the Activated Carbon Filters in order to reduce
the COD content and meet the discharge criteria.
After implementation reclaim water using Filtration System Package, so Activated Carbon
Filter will running continues. In case some suspended solids are present in the feed water,
Activated Carbon Filters would remove such a material from the water thus increasing their
pressure drop. In case pressure drop between each Activated Carbon Filter reach 0.7 bar (by PG-
7503 A/B and PG-7504 A/B), the filters need to be backwashed manually by using AC Filter
Feed and Backwash Pump and filtered water in the Filtered Water Pit.
Backwash Activated Carbon Filter is considered to be done automatically not manually.
Therefore, the system and all block valves in the activated carbon filter are considered for
improvement and modification.
TSR No : TSR-452-20-010 Prepared by : Elysa Setyo P. Signed:
Equipment : Tap Water System Checked by : G. Kunmartanto Signed:
Plant / Area : Water Treatment/WT Approved by : G. Kunmartanto Signed:
Page 7 of 8
PTD TSR REVIEW
PT. CHANDRA ASRI PETROCHEMICAL, Tbk
Jl. Raya Anyer Km. 123 Ciwandan , Cilegon.
Banten 42447, Indonesia
6. ECONOMIC
a) Potential benefit
- Improve WWT system thus to can support Company to Achieve GOLD PROPER award
- Re-Use water WWT Effluent to Treated Water and Reduce plant water consumption around
12 ton/h.
- Potential benefit to reduce KTI water 12 t/h is around $ 77,788.80 /Year
- Estimated ROI is 4 Years.
b) Investment Cost
No Description Price, USD
1. Filtration System Package $80,438
2. Total modification required exclude filter package $136,302
3. Installation $65,022
4. Contingency $21,674
Total investment $303,436
Disclaimer:
1) Basis investment cost is phase-1 ECR study which cover only material and installation, the cost may
be increased due to accuracy factor and others cost i.e. EPC service cost (Project management
service, Procurement service, Engineering service, Construction management service, Vendor
Supervision, etc.), Import duty, 2 years spare part, Construction and commissioning spare part, etc.
2) The investment cost only for filtration package with capacity 12 t/h and utilize as fire water make-up
(without RO).
7. CONCLUSION
Reclaim water project from effluent WWT using filtration system package is technically applicable
and feasible to recycle water as make-up fire-water which only used in case of emergency, then piping
will not scale unless liquid is constantly pumped through the piping network.
To ensure reliable removal of TDS, it would have to upgrade to RO system. However, if are option
of using in production water, then it will require additional treatment such as RO.
8. CONCLUSION
Attachment-1: PFD and P&ID Modification
Attachment-2: Tie-in List and Line List
Attachment-3: Equipment List
Attachment-4: Plot Plant
Attachment-5: Preliminary Cost Estimation
Attachment-6: Support Documents
TSR No : TSR-452-20-010 Prepared by : Elysa Setyo P. Signed:
Equipment : Tap Water System Checked by : G. Kunmartanto Signed:
Plant / Area : Water Treatment/WT Approved by : G. Kunmartanto Signed:
Page 8 of 8
