pY f lIffLif Yf J YJ wl fBt
Transcript of pY f lIffLif Yf J YJ wl fBt
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1 Opening and introduction at 9 00 9 30
2 Effluent discharge from different P P processes at 9 30 11 00
Coffee break at 11 00 11 30
3 Effluent treatment processes at 11 30 13 00
Primary treatment
Different secondary treatment solutions
Tertiary treatmentLunch
4 Effluent treatment processes continue5 Sludge dewatering
Break
6 Bleach filtrate recycle in kraft pulp mills7 Zero liquid discharge case presentation
at 13 00 14 30
at 14 30 15 00
at 15 00 16 00at 16 00 16 15
at 16 15 16 45
at 16 45 17 30
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VEOLlA Environnement Turnover Partition
45 20 15
Waste civil workwater FCC Spain
9
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One Group 4 Business Unitsl Ll
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Veolia Environnement 0
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VE LIAEnvironnement
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JVeolia Water
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1Veolia Water
Systems Brasil
HPD Aquaflowl Ll
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Veolia KeyF ures 112
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Data source VE results 2003l Ll
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y p ji AiVY kYt0 ytlfiYffYi 11Fhi tO hYf Xic h
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Pulp Papero Aracruz Veracel Klabin Cenibra
VCP Champion liP Bahia Sui
Arauco CMPC Cartiere BurgoKimberly Clark Stom Enso
oUPM Kymmene Myllykoski
VW5 The Partner of Industrials
Others marketso HPI CPIo Metal treatment
Powero Microelectronicso Automobileo Pharmaceuticals Cosmeticso Food Beverage industry l Ll
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UAJv
Present in LA since 1993
Operational Merge of OTV Brasil and USF Brasil
Two business lines
D B
Solutions
2003 revenue Euros 44 million
304 employees 50 in Brazil
40 engineers
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Veolia Water Systems Offerf y Sk
Design Build CapabilitiesDesign build solutions for municipalities and industrial
customers
Integrated water and wastewater systems wastewater
reuse sludge treatment
Engineering Construction services for Turn Keysupplies
Problem identification and treatability analysisProcess designBasic and detailed engineeringProject ManagementLocal equipment manufacturing
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AQF Global Total Water Management
FRavv iVa er mreafrr tEjnJ
Reve Qi mo is
SditerLiWik t r
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Stock Preparation and Paper Board Machine
4
P pri
Boco Machin
SV All OAF
i j 9 t litt rip
III Aquaflow Ltd by VEOLlA Water Systems
l1li USF Aquaflow Ltd
1999
1997
iii Ahlstrom Aquaflow Ltd 1989
III Ahlstrom Corporation 1987
III Enso Gutzeit Oy Stora Enso 1962
AQUAFLOW l LlV i i
Mr Heimo TOIVIAINEN
III VWS BUSINESS DEVELOPMENT DIRECTOR IN THE
P P INDUSTRY
III 1989 2004 MANAGING DIRECTOR OF AQUAFLOW
III STARTED IN 1974 IN EFFLUENT TREATMENT IN
THE P P ENSO GUTZEIT STORA ENSO
AHLSTROM
AQUAFLOW
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UAJv
Worldwide Pulp and Paper Production
l1li PRODUCTION
182 million ton pulp per year330 million ton paper per year
l1li WASTEWATER TO TREATMENT
About 30 35 billion m3 wastewater generated peryearAbout 25 30 million ton COD generated per year
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Factors Impacting on Wastewater
Composition and Characterists
1 Fibre raw material
2 Pulping and paper making process
3 Process status
4 Process operation
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piA j Y i kC
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Yh fPJf Pulping and Paper MillsMarket pulp mills
Raw material Pulp to free market or
To own paper mills
Integrated mills
Raw material Paperproduction
m m m m m m m m m m m m Pu I p
Non integrated paper millsRaw material r j
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Pulping Processes
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I Coated woodfree
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ll 0lJBleachedKraft Pulping
Wood handling CookingandW1lshing IScreeting
Oxygendelignification
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Bleached Kraft Pulping Discharges
Process COD
kg t pulpDebarking 0 10
Brovvnstock area 0 7
Bleach plant 25 55
Evaporation condensates 3 15
Spills 3 8
Total 31 95
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Main CompositionOrganic
Suspended
Dissolved
Inorganic
lignin derlVatilles
o bh ltllrlar 01 ra es sugilrsOnrga Ie aCh s
Chlor t cloIna e 9jlnJosNutrients N PJ
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Debarking
Wet vs dry debarking processWet debarking has higher discharge figures
Softwood higher Hardwood lower loads
Wastewater containsTSS bark residuai fibres inorganic matter
COD BOD dissolved and suspended material from logsNutrients P and N
Toxic compounds resin acids fatty acids
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Kraft Pulp Bleaching
GENERAL
Objective to bleach pulp from brown to white with oxidationchemicals Chlorine Dioxide Peroxide Ozone
Many processes most typical is Elemental Chlorine Free ECF
bleaching using Chlorine Dioxide
Total Chlorine Free TCF processes employ Peroxide Ozoneas oxidation chemicals
Bleach plant excess filtrate normally sewered since containsChlorides Heavy Metals and other inorganics that mayaccumulate in recovery cycle
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Kraft Pulp Bleaching
BLEACHING WASTEWATER COMPOSITION ANDLOADS ARE DEPENDENT ON
Washing loss Amount of COD entering the Bleach plantII Kappa factor Amount of lignin in pulp
III Cooking process Modified cookingIII Oxygen Delignification 00
iii Bleaching process Chemicals usedl1li C stage
III Elemental chlorine stageII Chlorine Dioxide
III TCF bleaching l UAv
Summary Bleached Kraft Pulping
Most common pulping process
Main organic load originating from bleach plantAbout 50 of the COD is caused by lignin productsthat are non or slowly biodegradableChlorinated organic compounds in bleach planteffluents AOX
Toxic compounds resin and fatty acids in
debarking and bleach plant effluents
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Sulphite Pulping
P ibarklng q9Qki E 7J III sllit19 BI tIi Q J iiJgPulpWood
Sulphurl99k lni liQu r
prm @ti m EWPQtion
1 lqtwBQlI
Totreatrrent
obarkjngemuentSmpendedE oiids
OrQanir rJ6ter
Extradjls
Nurients
CondensateAcgiCacidFurfural
Eleach ftltrate
CoIo0ffldsubsarces
NUtrientsMelais safts
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Sulphite Pulping Discharges
Dissolving pulp mills may have high dischargesHemicelulose
Cooking process generally driven further than inkraft pulping why bleach plant discharges are
normally lower
TCF bleaching common no chlorinated
compoundsCondenstes contain high amount of acetic acid andfurfural
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Summary Sulphite Pulping
Common in Central Europe and China but beingoutphased in other areas
Main organic load originating from condensates andbleach plantCondensates high in COD concentration
Acetic acid and furfural in condensates
Toxic compounds resin and fatty acids in
debarking and effluents
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Mechanical Pulping Processes
Processes include
Chemi thermomechanical pulping CTMPThermo mechanical pulping TMP
Stone Groundwood SGW or GW
Pressurised Groundwood PGW
Mechanical defibration in refiners or with stone
Chemical pretreatment in CTMP process Na2S03and or NaOH and Na2C03
Typical for mechanical processes is high yield on
wood
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Mechanical Pulping Processes
Mechanical pulping is normally INTEGRATED with
paper production
Newsprint paper TMP paper machine
Journal paper GW TMP paper machine
Some CTMP mills are stand alone others integrated
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P Process
CHIPWOoSHING IMREGNATION lSTSTA REFINING 2ND STAG REFlNING H RECOVERY
IPSCD 82 21 MN CD 82 11 MN
FRESHSmmmn
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Wastewater from Pul and Pa er P
wondH dling
DebarkingSuspended solids
Organic matter
Ex rEiet ves
Nutrients
P Process
Chemicals
lhipWashing
Chip WashingWood
OrganicmafferNutrients
Fi finjng
tieFl ecQle Y
Chemicals
IWashinj J BI j1JhinriTo board machine
Totreatm
Excess process water
Fibres
SulphurcompondsOrganicmatter
Nutrients
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Mechanical Pulping Discharges
Discharges from mechanical pulping processes are
primarily dependent on
Pulp yield
Pulp bleaching method
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Recycled FibreTwo main cartegories
Mechanical cleaning pulping of wastepaperlboard onlyTestliner
Corrugated mediumUncoated board
Mechanical cleaning and de InkingTissue
Printing and copy paperMagazineCoated board and cartonboard
Market DIP
Wastewater quality much dependent on wastepaperqualityMay have almost closed water loops l Ll
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Recycled Fibre Processes
II
I
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II
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Papermaking
In paper making processes water are recirculated ata high degree only excess water whitewater andrejects are normally discharged
Wastewater contaminants originate from
PulpRefining of pulpSizing agents starch
Fillers and Coating material caoline CaC03 etc
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Paoermakina
1OJDLY
QUu o aid DJ
HORTC CU ON
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mmmmmmmmmmmmmmmmmmmmmmmm mnm
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Special Features and Critical Topics
General
All mill departments must be reviewedWhich processes are applied debarking pulpingbleaching etc
Mill status old mills have generally considerablehigher discharges than new
level of spill control
level of water conservationReview actual variations of loads
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Special Features and Critical Topics
Process specific issues
Bleached kraft pulpingMost common chemical pulping processMain portion of organic load from bleachingBleach plant COD hard to degrade biologicallyOrganic load mainly dependent on wood specie kappa to BP andbleaching process
Unbleached kraft pulpingLevel of spills and washing loss of inmportanceWater use sometimes very high
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Special Features and Critical Topics
Sulphite pulpingMain organic load originating from condensates and bleach plantCondensates high in COD concentration
Acetic acid and furfural in condensates
Toxic compounds resin and fatty acids in debarking andeffluents
Mechanical pulping integrated with papermakingWastewater loads originates primarily from mechical pulpingHigh amount of collodial matter
Inorganic matter clay if filiers or coating applied in papermaking
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Special Features and Critical TopicsProcess specific issues
Recycled fibre
Discharges vary within wide range depending on technical
status
Some mills are almost effluent free
Non integrated papermakingLow amounts of organic matter
Wastewaters may be colored if colored paper are producedrvl ffA
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Aquaflow Competence Centerin the pap Industry
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jWPj Content of Presentation
PRIMARY TREATMENTII P P charasterlstlcsIII EquipmentIII Process selection
SECONDARY TREATMENTII P P charasterlstlcsIII MBP processIII Process selection
TERTIARY TREATMENTIII Need of tertiary treatmentIII Chemicals and processes
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What is Typical for Primary Treatment inP P Industry
l1li High and variable amount of suspended solids in the inlet
effluent
III good functioning of primary treatment is emphasized in specialsituations start ups stops and problems in the mill
III occasionally high amount of heavy inorganic material in the
effluent fillers coating DIP sludge lime mud
III poor sedimentation in certain effluents GW TMP CTMP coatingagents
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What is Typical for Primary Treatment inP P Industry
l1li Neutralization is normally requiredIII all the time
III or only for washing waters in mill stops
III Cooling is normally requiredIII effluent temperature is normally 40800C
III wood chips extractives and biological foulingl Ll
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Pri
Aquaflow Equipment
III Bucket screen
III Primary clarifiers
III Primary flotations
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Pri Treatment
Removes oversize solids which may interfere later
processes I I
I
go
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Pri
Primary Clarifier
I Walkway
Ec
Orivemechanism
Sludge pocket Overflow weir
Cone scraper
Rake arm Cage
Center column
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AF Float Flotation Unit DAF
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III Circular
III lJ 3 8 m up to 24 m
III Depth 1 3 m 1 8 m
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iii RectangularIII 4 2 m x 4 3 m 18 3 m2 up to 7 2 m x 14 7 m 105 m2
III Depth 1 3 m 1 8 m
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Priw
Equipment are Designed Just for P P
Industry Needs
III Robust equipment for 24 hid 365 d a
III Maintenance designed for 1 line systemsIII Capabilities to handle
III High 55 capacityIII Heavy sludgeIII Hot effluents
III Corrosive effluents
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Primary Sedimentation Selection Criteria
Low operating costsGood buffer capacity for solids
Simple processSuitable for very high solid contents
Big footprintLong retention time anaerobic acidification smells floatingLong suction line for sludge plugging of primary sludge
pumps
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Primary Flotation Selection Criteria
Pri
Small footprintNot sensitive for gases no anaerobic acidificationless smells
Good function with chemicals good results with small
light or charged particlesLower civil costs
Higher operating costsNo buffer capacity for solids
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lflExpected Purification Results in nmaryuSedimentation without Chemicals
Effluent type 55 content after
sedimentation mg l
Kraft pulp 70120
Paper board 40150
uncoated
Paper board 100300
coated
TMP GW 150400
CTMP 3001000
DIP 50200IIVEQ
Semichemical NSSC 3001000V it
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Treatment0 0 2
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What is Typical for Secondary Treafmertf6ift L
P P Industry
Relatively high COD concentration 500 13000 mg l
High temperature 35380C
Normally lack of nutrients 7 N P must be added
Some effluents are very sensitive for filament problemsIII VFA sugars resin and fatty acids TMP CTMP RCF OCC NSSCIII variation of produced paper or pulp grades
Variation of harmful chemicals for biologyIII biosidesIII washing agents and dispersing agentsIII coloursIII hydraulic oilIII black liqueur and soap spills chemical pulp miils
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Minimum Biosludge Production MBPPrimary Clarifier Aerobic Process Secondary Clarifier
I IXXXXI1 1
PrimarySludg
Air02
WasteActivatedSluclae
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Minimum Biosludge Production
Dispersed Bacteria in MBP Reactor
MBP
1st stage in the food chainl Ll
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Minimum Biosludge ProductionColony of Stalked Ciliates Eating
MBP
2nd stage in the food chainl Ll
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Minimum Biosludge ProductionCiliates and Suctoria
MBP
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Minimum Biosludge ProductionRotifers
MBP
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Minimum Biosludge ProductionSludge Production Factor
MBP
Sludge p oduction factor
Slart g MBP mod
C
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ml
1
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g g0
g g g0
g g g g0 0
0 0 00 0 0 0 0
0 0 0
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105
000
Treatment0i i iH
Minimum Biosludge Production MBPBenefits of MBP
l1li 30 50 lower sludge yieldl1li good settleability lexcellent effluent qualityl1li stable operation in fluctuating loading conditions
l1li less chemicals in sludge dewateringl1li higher dry solids in slude dewatering
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Treatment iMW
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MBBR Moving Bed Biofilm Reactorv
Process
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Treatment
MBBR Moving Bed Biofilm ReactorProcess
IIIIThe process is based on the biofilm principle and the core of the
process is the biofilm carrier elements made from
polyethylene or polypropylene with a density close to that of water
IIIIIThe carriers are designed to provide a larqe protected surface for the
bacteria culture
IIIIThe reactors are filled up to 67 of their volume with these carrier
elements
IIIIThe biofilm carrier elements are kept suspended in the water by air
from the diffusers in the aerobic reactors and by means of a mixer in the
anoxic reactors
i iz ii AMNW i
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74ljII0 JA y 1h0 Y fk Y 1 YcVtP i CA Ai s
i41Il IfR ProcessJk il
Moving Bed Biofilm Reactor
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Treatment
i 0 JhPi1 9 i N ld i Jb 0 I
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MBBR Moving Bed Biofilm ReactorProcess Different Carriers
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TreatmentUL d Ri
MBBR Moving Bed Biofilm Reactor Process
TreatmentfS y i Xi
MBBR Moving Bed Biofilm ReactorProcess Mixing in Reactors
Aerobic reactor Anoxic reactor
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60o
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Treatment ti 1@0 0 kMj iii
yn ti 1 04Y ifE iA t HB rJiJ2j1 Ttf ii t d
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MBBR Moving Bed Biofilm Reactor ProcessMBBR as solebiotreatment
MBBR as pretreatment
roughingBAS
MBBR as posttreatment
polishing
MBBR in
activated
sludgeHYBASjIFAS
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Q iJ C Y
MBBR Moving Bed Biofilm ReactorProcess Future Expansion
100
kgd
Increase filling degree by adding more
biomedia
200
kgd
Needs of Tertiary Treatment
III environmental requirements for
III PhosphorousIII COD
IIIIAOX
III Colour
III High SS
III 80D
III Nitrogenl Ll
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Needs of Tertiary Treatment
III Renovation of old lagoon based biological processes
III Much lower investment costs than completely new
biological process
IIIIPolishing process for difficult or filamentous sensitive
effluents
IIIIAfter high loaded processes
WELL DESIGNED TERTIARY TREATMENT GIVES
SAFETY FOR TOTAL TREATMENT PROCESS l LlV
Processes
III Chemical coagulation and or flocculation
III Filtration
II Sand filtration
II Microfiltration
II Membrane processes
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Chemical Coagulation and Flocculation
Coagulation chemicals used
III Aluminium sulphate AVR optimum pH 5 5 5
III Polyaluminiumchloride PAC optimum pH 5 5 5
III Ferric sulphate optimum pH 4 5
III Ferrous sulphate H202 Fenton or Fennotriox
III Optimum pH 3 3 5
III Organic coagulantsillUme
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Chemical Coagulation and Flocculation
Flocculation chemicals used
III Polyacrylamides PolymersIII Bentonite
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Chemical Coagulation and Flocculation
Alternative separation processes
l1li FlotationIII Very reliable process for P P effluents
II1II Sedimentation
II1II FiltrationIII Can be alternative only for low COD effluents
III Not suitable for filamentous bulking problems
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VM JY PWiX rJfhWp i1 fAsp 5AffU
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YiFiltration Process
IIIIIPossibility to very low 55 content P N
IIIIOnly for low 55 content effluents
IliSand filtration microfilters
l1li No reduction of dissolved substances without
l1li chemicals
III Membrane processesl1li selective treatment based on molecular size
l1li high investment and operating costs
l1li reject disposall1li fouling
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UAJv
P T Riau Andalan Pulp Paper Sumatra Indonesia
Kraft pulp mill 330 000 m3 d flow
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Stora Enso Port Hawkesbury MillCanada
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Stora Enso Norrsundet Mill Sweden Modification ofAerated Lagoon to Advanced AST Plant
MBP selector process
chlorate removal
selector pluf flow
SVI60
70 mg I
Sludge yield 0 14 kg kg COD
All targets of the mill were met
excellent treatment results
excellent availability
Celulosa Arauco y Constitucion S A Valdivia MillsChile
MBP Selector Process
Enchanced chlorate
removal
Selector plug flow
Tertiary treatment
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ytelulosa Arauco y Constitucion S A
Nueva Aldea Mills Chile
Production 555 000 t a of pine and eucalyptus pulp l fJAV i i
Mondi Ltd Richards Bay Pulp Mill South Africa
Minimization of Polution ofthe Rebuild Mill Based on BAT
Treatment
Aquaflow MBP selector process
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Kappa Kraftliner Pitea Sweden
Production 700 000 ita of paper and paperboard500 000 ita of pulp kraft linerboard l Ll
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8tora Enso Celbi Pulp Mill Portugal
Production 295 000 Adtla ECF bleached
eucalyptus market kraft pulp l Llv
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Two Stage MBBR at Backhammar Kraft Mill Sweden
Pro
Activated Sludge treatment BAS
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8tora Enso Varkaus Mills Finland
Aquaflow s AF Float tertiary flotation planttreating 60 000 m3 d biologically treated effluent
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M reallielahti Mills Finland
AF Float 9 5 1 3 tertiary treatment DAF final
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