Analysis and Reduction of Wastewater Loads of a Paper Plant for the Production Of

BUT Master2012 (UT) Fachprojekt University of Applied Sciences Upper Austria FH – Wels Analysis and reduction of wastewater loads of a paper plant for the production of medical and hygiene products Fachprojekt Andreas Feldbauer, B.Sc. S1210447006 March 3rd, 2014 Supervised by: Dipl.–Ing. Dr. nat.tech. Kiril Atanasoff BUT Master2012 (UT) Fachprojekt Abstract A high amount of water is needed for several processes regarding the production of pulp and paper. Traditionally the pulp and paper industry is an eco-friendly one with inherently only low and slightly harmful emissions. Nonetheless the production process causes wastewater loads of organic carbon compounds, which have to be treated. The company Paul Hartmann GmbH in Grimmenstein runs a pulp factory which produces pulp for medical and hygiene products. The wastewater is physically and mechanically pretreated and afterwards discharged into the municipal wastewater treatment plant Grimmenstein-Edlitz-Thomasberg. The wastewater loads occasionally occur to be too high (peak loads), which causes severe problems in the receiving municipal wastewater treatment plant. In terms of content the emphasis of this paper is on the analysis of the correlation of the Paul Hartmann GmbH’s effluent wastewater loads in comparison with the wastewater loads of the municipal wastewater treatment plant Grimmenstein- Edlitz-Thomasberg including their causes and consequences, such as peak loads. Furthermore it provides an overview of the current state of the art wastewater treatment methods at pulp and paper plants and also an exposition of the effects on the municipal sewage plant. I BUT Master 2012 (UT) Fachprojekt Table of contents 1 Introduction ..................................................................................... 1 1.1 Description of the Company ................................................................ 1 1.2 Description of the plant ...................................................................... 2 2 Situation of water and wastewater in Germany ..................................... 4 3 Biological wastewater treatment ......................................................... 5 3.1 Anaerobic wastewater treatment ......................................................... 7 1.1.1. Systems using suspended biomass.............................................. 8 1.1.2. Fixed bed processes .................................................................. 9 1.1.3. Combined processes.................................................................. 9 3.2 Aerobic wastewater treatment .......................................................... 10 1.1.4. Activated sludge process.......................................................... 10 1.1.5. The membrane-bioreactor ........................................................ 11 1.1.6. Trickling filters........................................................................ 11 1.1.7. High-rate carrier biology .......................................................... 12 1.1.8. Submerged fix-bed reactors ..................................................... 13 1.1.9. Moving bed biofilm reactor ....................................................... 13 1.1.10. Stabilization ponds .................................................................. 14 3.3 Applied process combinations ........................................................... 15 4 Description of the wastewater treatment of the Paul Hartmann GmbH ... 16 4.1 Physical-mechanical pretreatment of the wastewater ........................... 16 5 Problem ......................................................................................... 18 5.1 Analysis of correlation of the wastewater loads ................................... 19 1.1.11. Statistical analysis .................................................................. 19 5.2 Comparison and interpretation of the time series ................................ 20 1.1.12. Wastewater flow ..................................................................... 20 5.2.1 pH – values .............................................................................. 24 5.2.2 PE60/BOD5 ................................................................................. 28 II BUT Master 2012 (UT) Fachprojekt 5.2.3 PE120/COD ................................................................................. 36 5.2.4 Correlation of the outflow loads of the Paul Hartmann GmbH and the inflow loads to municipal sewage plant (regression analysis BOD5/COD) ...... 43 5.2.5 85% Percentile .......................................................................... 50 5.3 Statement of reason for increased wastewater loads from Paul Hartmann GmbH .................................................................................................... 54 5.4 Ratio of COD filtrate water to COD sediment ....................................... 54 5.5 Effect of the use of wet strength agents on COD loads ......................... 57 5.5.1 Usage of wet strength agents ...................................................... 57 5.5.2 Effects of wet strength agents on the COD .................................... 59 6 Impact on the local sewage plant ...................................................... 61 6.1 Description of permission according to the water legislation assessment NKW2-WA-0477/002................................................................................ 61 6.2 Facilities......................................................................................... 61 6.3 Original design values according to the Wasserrechtsbescheid .............. 62 6.4 Project 2009 ................................................................................... 63 6.4.1 Occasion ................................................................................... 63 6.4.2 Purpose .................................................................................... 63 6.4.3 Changed design values for consensus adjustment .......................... 64 6.4.4 Operating results 2012 ............................................................... 65 6.4.5 Recalculation of the activated sludge plant .................................... 66 6.4.6 Results of the Recalculation ........................................................ 66 7 Discussion ...................................................................................... 68 8 References ..................................................................................... 70 9 Annex ............................................................................................ 72 III BUT Master 2012 (UT) Fachprojekt Table of Figures Figure 1: Plant in Grimmenstein ..................................................................... 1 Figure 2: Site plan ........................................................................................ 3 Figure 3: Mean ratios of BOD/COD ................................................................. 6 Figure 4: Process flow diagram .................................................................... 17 Figure 5: Wastewater volume 2012 .............................................................. 21 Figure 6: Wastewater volume 2011 .............................................................. 22 Figure 7: Wastewater volume 2010 .............................................................. 23 Figure 8: pH - values 2012 .......................................................................... 25 Figure 9: pH - values 2011 .......................................................................... 26 Figure 10: pH - values 2010 ........................................................................ 27 Figure 11: PE60 values 2012 ......................................................................... 29 Figure 12: PE60 values 2011 ......................................................................... 30 Figure 13: PE60 values 2010 ......................................................................... 31 Figure 14: BOD5 values 2012 ....................................................................... 32 Figure 15: BOD5 values 2011 ....................................................................... 33 Figure 16: BOD5 values 2010 ....................................................................... 34 Figure 17: BOD5 and COD outflow loads Hartmann 2012 ................................. 35 Figure 18: PE120 values 2012 ..................................................................... 37 Figure 19: PE120 values 2011 ..................................................................... 38 Figure 20: PE120 values 2010 ..................................................................... 39 Figure 21: COD values 2012 ........................................................................ 40 Figure 22: COD values 2011 ........................................................................ 41 Figure 23: COD values 2010 ........................................................................ 42 Figure 24: Regression analysis BOD5 2012 ..................................................... 44 Figure 25: Regression analysis BOD5 2011 .................................................... 45 Figure 26: Regression analysis BOD5 2010 .................................................... 46 Figure 27: Regression analysis COD 2012 ..................................................... 47 Figure 28: Regression analysis COD 2011 ..................................................... 48 Figure 29: Regression analysis COD 2010 ....................................................

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