ENGINEER’S STICKER: CONTRACTOR’S STICKER:

01 For Approval FLS MAS AEN 26.05.2024

00 For Approval FLS MAS AEN 19.04.2024
REV ISSUED FOR PREPARED BY CHECKED BY APPROVED BY DATE

‫اﻟﻣﻣﻠﻛﺔ اﻟﻌرﺑﯾﺔ اﻟﺳﻌودﯾﺔ‬

KINGDOM OF SAUDI ARABIA

‫ﺷرﻛﺔ اﻟﻣﯾﺎه اﻟوطﻧﯾﺔ‬

NATIONAL WATER COMPANY (NWC)

‫رﻗم اﻟﻣﺷروع‬
PROJECT NO.
EXPANSION OF AL KHOBAR SEWAGE TREATMENT
701230311 PLANT PROJECT

‫االستشاري‬ ETS ENGINEERING CONSULTANCES

ENGINEER

‫اﻟﻣﻘﺎول‬ AL YAMAMA COMPANY FOR

CONTRACTOR TRADING AND CONTRACTING

‫استشاري التصميم‬
DESIGN
CONSULTANT

Document Title:

PROCESS DESCRIPTION
Sheet Rev.
Document No.:
701230311-KHR-PAS-010GEN-HYD-RE-00001 Page 1 of 60 01
 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 2 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

TABLE OF CONTENTS
ABBREVIATIONS .................................................................................. 5
1. Introduction ..................................................................................... 7
1.1 GENERAL .....................................................................................................................7
1.2 PLANT LOCATION AND FOOTPRINT ......................................................................7
1.3 INTERFERENCE WITH OTHER EXISTING PLANTS ...............................................................9

2. Design standard .............................................................................. 9

3. GENERAL Arrangement OF THE WWTP ..................................... 10
4. PLANT SCHEMATIC AND DIAGRAM ........................................... 12
5. Basic design data.......................................................................... 13
5.1 DESIGN FLOWS AND POLLUTANT LOADS ..................................................................... 13
5.2 EFFLUENT QUALITY CRITERIA .................................................................................... 15

6. Process Description ..................................................................... 16

6.1 GENERAL .................................................................................................................. 16
6.2 MECHANICAL TREATMENT STAGE ..................................................................... 16
6.2.1 Inlet Chamber .................................................................................................................. 16
6.2.2 Trucked Sewage Receiving Station ................................................................................. 16
6.2.3 Coarse Screens ............................................................................................................... 17
6.2.4 Fine Screens .................................................................................................................... 19
6.2.5 Inlet Quality Measurements ............................................................................................. 20
6.2.6 Grit & Grease Chambers ................................................................................................. 20
6.2.7 Bypass Chamber PST ..................................................................................................... 22
6.2.8 Influent Flow Measurement ............................................................................................. 22
6.3 PRIMARY TREATMENT STAGE ...................................................................................... 23
6.3.1 Distribution Chambers PST ............................................................................................. 23
6.3.2 Primary Sedimentation Tank ........................................................................................... 23
6.3.3 Bypass Collection Chamber PST .................................................................................... 24
6.4 BIOLOGICAL WASTEWATER TREATMENT ......................................................... 25
6.4.1 Return Sludge Mixing Chamber ....................................................................................... 25
6.4.2 Distribution Chambers AST ............................................................................................. 25
6.4.3 Activated Sludge Process ................................................................................................ 25
6.4.4 Anaerobic Bio-P Tanks .................................................................................................... 26
6.4.5 Ferric Chloride Dosing Station ......................................................................................... 27
6.4.6 Activated Sludge Tank (Carbon Removal, Nitrification and Denitrification) .................... 28
6.4.7 Distribution Chamber SST ............................................................................................... 30
6.4.8 Secondary Sedimentation Tank ....................................................................................... 31
6.5 TERTIARY TREATMENT................................................................................................ 32
6.5.1 Filter Station ..................................................................................................................... 32
6.5.2 Dirty Backwash Pumping Station ..................................................................................... 33
6.5.3 Effluent Flow Measurement ............................................................................................. 34
6.5.4 NaOCl Generation Plant (Disinfection) ............................................................................ 34
6.5.5 Chlorine Contact Tank ..................................................................................................... 35
6.5.6 Outlet Quality Measurement ............................................................................................ 36
6.5.7 Service Water Pumping Station ....................................................................................... 36
6.5.8 Treated Effluent Storage Tank ......................................................................................... 37
6.5.9 Sea Outfall Pumping Station and Pipeline ....................................................................... 38
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6.6 SLUDGE TREATMENT .................................................................................................. 39

6.6.1 Primary Sludge & Scum Pumping Stations ..................................................................... 39
6.6.2 Return & Surplus Sludge and Secondary Scum Pumping Stations ................................ 39
6.6.3 SAS Balancing Tanks ...................................................................................................... 41
6.6.4 Mechanical Sludge Thickening Plant ............................................................................... 41
6.6.5 Sludge Mixing Tanks ....................................................................................................... 43
6.6.6 Digester Feed Pumping Station ....................................................................................... 44
6.6.7 Anaerobic Sludge Digestion ............................................................................................ 44
6.6.8 Gas Utilisation Plant......................................................................................................... 50
6.6.9 Digested Sludge Storage Tanks ...................................................................................... 55
6.6.10 Dewatering Feed Pumping Station .............................................................................. 56
6.6.11 Sludge Dewatering Plant ............................................................................................. 57
6.6.12 Sludge Storage Area ................................................................................................... 58
6.6.13 Returns Liquor Pumping Station ................................................................................. 58
6.7 ODOUR TREATMENT ................................................................................................... 60
6.7.1 Odour Control Unit ........................................................................................................... 60
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List of Figures

Figure 1: Expansion of Al Khobar STP Site Location……………………………………….08

Figure 2: Expansion of Al Khobar STP Schematic Diagram………………….…..………..12

Figure 3: Schematic Diagram for A²O process……………………………………………….26

Figure 4: ARTELIA’s Digester Equipment……………………………………………….45

List of Tables

Table 1: Hydraulic Flows of Al Khobar Expansion STP………………….....…………...13

Table 2: Pollution Concentrations of Al Khobar Expansion STP……………..…..………....14

Table 3: Treated Wastewater Quality Standards ……………………………………..…..….15

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National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

ABBREVIATIONS

NWC National Water Company

STP Sewage Treatment Plant
RFP Request for Proposal
PE People Equivalent
DWA Deutsche Vereinigung für Wasserwirtschaft, Abwasser und
Abfall (translation: German Association for Water, Wastewater
ATV Abwassertechnischen
and Waste) Vereinigung (translation: Wastewater
Technology Association)
WEF Water Environment Federation
ASCE American Society of Civil Engineers
SI International Unit System
PST Primary Sedimentation Tanks
AST Activated Sludge Tanks
SST Secondary Sedimentation Tanks
CCT Chlorine Contact Tank
TEST Treated Effluent Storage Tank
RAS Return Activated Sludge
SAS Surplus Activated Sludge
TDS Total Dissolved Solids
BOD5 Biochemical Oxygen Demand
COD Chemical Oxygen Demand
TSS Total Suspended Solids
TKN Total Kjeldahl Nitrogen
NH4-N Ammonia Nitrogen
Ptotal Total Phosphorus
NO3-N Nitrate Nitrogen
NaOCl Sodium Hypochlorite
NaCl Sodium Chloride
FeCl3 Ferric Chloride
FOG Fat, Oil and Grease
NTU Nephelometric Turbidity unit
CFU Colony Forming Unit
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MPN Most Probable Number

FC Fecal Coliforms
CHP Combined Heat and Power
°C Celsius
MLSS Mixed Liquor Suspended Solids
PAOs Phosphorus Accumulating Organisms
MAP Magnesium Ammonium Phosphate
CEPT Chemically Enhanced Primary Treatment
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1. INTRODUCTION

1.1 GENERAL
The scope of this project includes design, supply, construction and testing & commissioning of
the new expansion of Al Khobar Sewage Treatment Plant (STP), which will be capable to treat
an average daily flow of 200,000 m3/d. The new plant will be located in the same plot area of
existing Al Khobar STPs and Ajyal STP.

Generally, the design criteria will be based on the Employer Requirements (National Water
Company (NWC) Design Manual) according to the German Association for Water, Wastewater
and Waste (DWA) guide lines (former ATV) and implementing same process treatments and
technologies as Ajyal STP as requested by the Employer.

The STP will have biological nutrient removal process to achieve organic matter, nitrogen and
phosphorus removal, with secondary clarifiers. Sludge stabilization will be achieved by
anaerobic sludge digestion process.

1.2 PLANT LOCATION AND FOOTPRINT

Expansion of Al Khobar STP will be located at the same plot area of existing Al Khobar STPs
and Ajyal STP as shown in below Figure 1.

The plant will have a total area of approximately 176,000 m2 (500m x 352m).
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Figure 1: Expansion of Al Khobar STP Site Location

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1.3 INTERFERENCE WITH OTHER EXISTING PLANTS

The new Expansion of Al Khobar STP will interfere with other existing plants, which are located
on the same plot area:

• As part of the expansion of Al Khobar STP’s scope, a new Sea Outfall Pumping Station
and pipeline will be provided, which will serve all the plants; existing Al Khobar STP,
existing Ajyal STP and the new expansion of Al Khobar STP.
• As part of the expansion of Al Khobar STP’s scope, a new disinfection plant (Electro-
chlorination plant) will be provided for existing Al Khobar STP.
• Treated effluent from the new Expansion of Al Khobar STP will be discharged to the
existing Irrigation Pumping Station.

2. DESIGN STANDARD

The proposed sewage treatment plant will comprise a biological treatment stage with a design
capacity of around 888,889 PE based on 225 l/(E*d).
The STP is designed in accordance with the Tender specifications and published standards.
Most references applied in our design can be found in the following literature:

• Standard ATV-DVWK-A131: "Dimensioning of Single-Stage Activated Sludge Plants"),

edition May 2000, issued by DWA (former ATV-DVWK – German Association for
Water, Wastewater and Waste). This document is the design guideline used all over
Germany for the design of municipal wastewater treatment plants and is also worldwide
accepted as a design basis.

• Metcalf & Eddy, Wastewater Engineering

• WEF/ASCE Design Standards

• ATV- Handbuch, Mechanische Abwasserreinigung, 4. Auflage

• Technical Standard Specifications for Wastewater System, Sewage Pumps Stations,

Force (Pressure) Mains, TSE Network, Design Manual
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3. GENERAL ARRANGEMENT OF THE WWTP

The main process units are:

1. Preliminary Treatment

• Trucked Sewage Receiving Station

• Coarse Screens

• Fine Screens

• Grit and Grease Removal Chambers

2. Primary Treatment

• Primary Sedimentation Tanks (PSTs)

• Primary Sludge Pumping Station

3. Biological Treatment

• Activated Sludge Tanks (ASTs)

• Aeration Blower Station

• Secondary Sedimentation Tanks (SSTs)

• Return Activated Sludge (RAS) Pumping Station

• Surplus Activated Sludge (SAS) Pumping Station

4. Tertiary Treatment & Sea Outfall

• Filter Station

• Disinfection by generated NaOCl on site

• Chlorine Contact Tank (CCT)

• Treated Effluent Storage Tank (TEST)

• Sea Outfall Pipeline & Pumping Station

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5. Sludge Treatment

• Mechanical Sludge Thickening

• Anaerobic Sludge Digestion

• Mechanical Sludge Dewatering

• Sludge Storage Area

6. Biogas Systems

• Biogas Desulphurization

• Gas Flare

• Gas Holder

• Co-generation Unit

• Boiler Unit

7. Odor Treatment

• Odour Control Unit

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4. PLANT SCHEMATIC AND DIAGRAM

Figure 2: Expansion of Al Khobar STP Schematic Diagram

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5. BASIC DESIGN DATA

5.1 DESIGN FLOWS AND POLLUTANT LOADS

Table 1 shows design hydraulic flowrates of Expansion of Al Khobar STP.

Table 1: Hydraulic Flows of Al Khobar Expansion STP

Parameter Unit Design Flows

Average daily flow* m3/d 200,000
Peak flow** m3/h 13,450

Minimum flow*** m3/h 4,167

* Daily average flowrate is based on the RFP

** Peak flow is calculated accordingly to NWC Specifications (Design Manual)

*** Minimum flow is estimated as 50% of average daily flow

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Table 2 shows pollution concentrations that is used for Process Design Calculation of
Expansion of Al Khobar STP.

Table 2: Pollution Concentrations of Al Khobar Expansion STP

Parameters Unit Concentrations Concentrations Concentrations

(Design Maximum) * (Actual Average) ** (Actual Minimum) ***

pH - 6 – 8.5 6 – 8.5 6 – 8.5

Temperature °C 20 (min.) – 28 (avg.) – 38 20 (min.) – 28 (avg.) – 38 20 (min.) – 28 (avg.) – 38

(max.) (max.) (max.)

TDS mg/L < 2,500 < 2,500 < 2,500

BOD5 mg/L 250 195 122

COD mg/L 500 300 284

TSS mg/L 290 176 119

TKN mg/L 50 36 32

NH4-N mg/L 27 27 23.8

Ptotal mg/L 8 5 4.3

* Concentrations under "Concentrations (Design Maximum)": are taken from NWC Design
Manual, Table 6-1 according to tender clarifications, dated on 10.01.2023.

** Concentrations under "Concentrations (Actual Average)": are average loads of existing

Al Khobar STP over the whole year of 2023.

*** Concentrations under "Concentrations (Actual Minimum)": are lowest organic load day
of existing Al-Khobar STP in 2023.
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5.2 EFFLUENT QUALITY CRITERIA

Table 3 shows treated wastewater quality standards that need to be met.

Table 3: Treated Wastewater Quality Standards

Parameter Symbol Unit Effluent Effluent Effluent

Parameters Parameters Parameters
(Design Max.) (Actual Avg.) (Actual Min.)
Total Suspended Solids TSS mg/L 10 10 10

Turbidity Turb NTU 5 5 5

pH pH - 6.0 – 8.4 6.0 – 8.4 6.0 – 8.4

Free Chlorine Cl2 mg/L ≥ 0.5 ≥ 0.5 ≥ 0.5

Biological Oxygen Demand over BOD5 mg/L 6.5

10 6.5
10 6.5
10
5 days
Chemical Oxygen Demand COD mg/L 50 20 20

Fat, Oil and Grease FOG - None None None

Nitrate-Nitrogen NO3-N mg/L 10 10 10

Ammonia-Nitrogen NH4-N mg/L 1.9 1.9 1.9

Phosphate PO4 mg/L 1 1 1

Total Coliform Bacteria - MPN/100m 1000 1000 1000

Fecal Coliforms FC CFU/100ml 2.2 2.2 2.2

Viable eggs of intestinal worms - No/L 1 1 1

The effluent characteristics will be taken in homogeneous, unsettled 24-hour composite

sample in the outlet chamber of Chlorine Contact Tank.

Note: Since the wastewater received will be municipal type wastewater and will not contain
any toxic substance for the biomass, therefore, its confirmed that these effluent characteristics
will be achieved with the proposed treatment process.
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6. PROCESS DESCRIPTION

6.1 GENERAL
The process of the wastewater treatment consists of mechanical treatment stage, primary
treatment stage, biological treatment stage, tertiary treatment stage, sludge treatment stage
and odour treatment. For further detailed information, refer to the process design calculation,
hydraulic calculation, hydraulic profile, site layout drawing, general arrangement drawings,
process flow diagram, mass balance and piping & instrumentation diagrams.

6.2 MECHANICAL TREATMENT STAGE

6.2.1 Inlet Chamber

Function
Connection point of inlet raw wastewater pipe and distribution of raw sewage to the screening
facility
Explanatory Remarks
The Inlet Chamber will be part of the screening building and will receive the raw sewage via
pressure pipeline transferring raw wastewater from all inlet pipes that are currently feeding
existing Al Khobar STP and distribute it to the two streams of screening facilities.
An emergency overflow using fixed weir will be provided for the Inlet Chamber. This emergency
overflow will be fitted with a system for flow indication and metering (i.e., ultrasonic flow
measurement devices). Untreated wastewater will be transferred, via the by- pass pipe to the
existing lagoons. The by-pass will be subjected to emergency cases only.
The Inlet Chamber will be completely covered, served by the odorous air extraction system
and connected to an odorous air treatment system.

6.2.2 Trucked Sewage Receiving Station

Function

Faecal sludge unloading and discharging to the inlet works of the plant
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Client: Contract No.: Document Number:

Rev 01 Page 17 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

Main Design Data

Number of trucked sewage screening units 1

Trucked sewage screening unit capacity 216 m³/hr

Clear opening 10 mm

Number of screenings containers 1

Capacity of screenings container 1 m³

Number of trucked sewage transfer pumps 2 (1 duty + 1 standby)

Trucked sewage transfer pumps capacity 396 m³/hr at 17 mWC

Type of sewage transfer pumps Centrifugal (submersible)

Explanatory Remarks

The facility mainly consists of three (3) sewage tanker truck unloading stations including flow
and quality monitoring (pH and conductivity), a sewage collection system, a screen for
removing large objects from the sewage and a pumping station for conveying the screened the
external septages delivered by trucks and other internal drainages to the Inlet Chamber
upstream of the screening facility.

The screenings from the trucked sewage screen will be thrown off into a container. The trucked
sewage transfer pumps will be controlled by the level measurement of the pump sump.

6.2.3 Coarse Screens

Function

Removal of coarse particles and protection of the downstream machinery

Main Design Data

Number of coarse screen units 6 (4 duty + 2 standby)

Type Mechanically operated bar screen

Capacity per unit 3,363 m³/h

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National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

Bar spacing 20 mm

Number of coarse screenings conveyors 2

Capacity of coarse screenings conveyor 4 m³/h

Number of coarse screenings wash presses 2

Number of coarse screenings wash press 4 m³/h

Number of coarse screenings containers 2

Capacity of coarse screenings container 10 m³

Explanatory Remarks
A bar screen is a mechanical filter used to remove large objects, such as rags and plastics,
from wastewater. It is part of the physical treatment and typically is the first being installed at
the influent to a wastewater treatment plant.
Six mechanical coarse screens (4 duty + 2 standby), which are designed for the maximum
hourly waste water flow-rate during rainy weather, will be provided for the protection of the fine
screens downstream.
The screens will be cleaned automatically and controlled by a water level difference measuring
on each screen. The cleaning system will start to operate when the level difference reaches to
a set point. Moreover, even if the level difference stays below the set point, the cleaning system
will also start to operate after the adjusted time interval.
Screened materials from the coarse screens will be discharged into screw conveyors and then
into wash presses where they will be exposed to powerful introduction of wash water. The
washing achieves perfect separation of organic particles and thus effective screenings
washing. After the screenings are compacted, they shall be directly disposed in to containers.
The conveyors and wash presses will be automatically switched on and off according to the
operation of the coarse screens.
Coarse screening channels, coarse screens, conveyors and screening wash presses will be
closed and collected air will be transferred to odour treatment unit.
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6.2.4 Fine Screens

Function

Removal of fine particles and protection of the downstream machinery

Main Design Data

Number of fine screen units 6 (4 duty + 2 standby)

Type Mechanically operated perforated plate

Capacity per unit 3,363 m³/h

Opening’s size 6 mm

Number of fine screenings conveyors 2

Capacity of fine screenings conveyor 4 m³/h

Number of fine screenings wash presses 2

Number of fine screenings wash press 4 m³/h

Number of fine screenings containers 2

Capacity of fine screenings container 10 m³

Explanatory Remarks
Perforated plate screens will be provided after the coarse screens inside the screen building.
The screenings are kept by the perforated plates. As the endless perforated chain is rotating
in the channel, the screenings are slowly separated from the water stream.
Six mechanical fine screens (4 duty + 2 standby), which are designed for the maximum hourly
waste water flow-rate during rainy weather, will be provided for the protection of the
downstream facilities.
The screens will be cleaned automatically and controlled by a water level difference measuring
on each screen. The cleaning system will start to operate when the level difference reaches to
a set point. Moreover, even if the level difference stays below the set point, the cleaning system
will also start to operate after the adjusted time interval.
Screened materials from the fine screens will be discharged into screw conveyors and then
into wash presses where they will be exposed to powerful introduction of wash water. The
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Client: Contract No.: Document Number:

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National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

washing achieves perfect separation of organic particles and thus effective screenings
washing. After the screenings are compacted, they shall be directly disposed in to containers.
The conveyors and wash presses will be automatically switched on and off according to the
operation of the fine screens.
Fine screening channels, fine screens, conveyors and screening wash presses will be closed
and collected air will be transferred to odour treatment unit.

6.2.5 Inlet Quality Measurements

Function
Sampling of the influent wastewater

Explanatory Remarks
An automatic sampler will be installed after pre-treatment to collect and store water samples
from the influent. Influent quality control for pH value, conductivity and temperature will be also
located at the same location. The automatic sampler can take flow proportional 24-hour-
composite samples. All the necessary equipment will be provided.

6.2.6 Grit & Grease Chambers

Function
Removal of grit and grease

Main Design Data

Number of grit and grease chambers 4

Number of bridge scrapers 4

Width of each grit chamber 3.8 m

Width of each grease chamber 1.45 m

Depth of each grit chamber 4.7 m

Length of each chamber 38 m

Number of grit pumps 4

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Client: Contract No.: Document Number:

Rev 01
1 Page 21 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

Capacity of each grit pump 36 m³/h at 12 mWC

Type of grit pumps Centrifugal (submersible)

Number of grit classifiers 4 (2 duty + 2 standby)

Capacity of each grit classifier 72 m³/h

Number of grit storage containers 4 (2 duty + 2 standby)

Capacity of grit storage container 10 m³

Number of grit blowers 6 (4 duty + 2 standby)

Capacity of each grit blower 700 Nm³/h at 480 mbar

Type of each grit blower Positive displacement

Number of grease pumps 2 (1 duty + 1 standby)

Capacity of each grease pump 20 m³/h at 40 mWC

Type of each grease pump Eccentric screw

Explanatory Remarks
Grit shall be removed in order to reduce risk of damage to the mechanical equipment in the
following treatment units and grease shall be removed to avoid non-aesthetic conditions
caused by the volatile organics and malodorous floating sludge.
After the fine screens, the wastewater will flow to four aerated grit and grease removal
chambers (longitudinal aerated grit chamber type with separate grease removal compartment
along the side). The purpose of these units is to remove the sand particles larger than 0.20
mm from the waste water with an efficiency of 90%.
An aerated grit chamber consists of a standard spiral flow aeration tank provided with air
diffusion tubes placed on one side of the tank. The grit particles tend to settle down to the
bottom of the tank at rates dependent upon the particle size and the bottom velocity of roll of
the spiral flow, which in turn depends on the rate of air diffusion through diffuser tubes and
shape of aeration tank. The heavier particles settle down whereas the lighter organic particles
are carried with roll of the spiral motion. The settled grit from the bottom of the channel will be
transferred to the grit channels and then transferred by gravity to the grit classifiers. Grit
classifiers will separate water from grit; water (supernatant) will flow to the sump pump of
trucked sewage receiving station, while grit will be stored in containers.
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The floated grease and oil will be pushed by grease blades to a grease chamber, which is
placed at the head of each grit and grease removal chamber. On the scrapers way back to the
head, the grease will be pushed into the grease chambers via motorized penstocks. The
grease is collected in the two grease collection chambers and then pumped to the anaerobic
sludge tanks (seeding mixers) by grease pumps.
Positive displacement type blowers will be provided for the air supply to the grit chambers.
Grit and grease chambers and grit classifiers will be closed and collected air will be transferred
to odour treatment unit.
Local control panels will control the moving drives and shields of the scrapers of grit and grease
removal chambers.

6.2.7 Bypass Chamber PST

Function

Provide Bypass of PST (Upstream)

Explanatory Remarks

In order to achieve a maximum operation flexibility during start up and operation, primary
sedimentation tanks by-pass will be provided to be directly transferred to the Activated Sludge
Tanks. This will give more operational flexibility during operation of the plant, if its needed.

6.2.8 Influent Flow Measurement

Function

Determination of the inlet wastewater flow

Explanatory Remarks

Influent wastewater flow will be measured by means of two electromagnetic flow meters,
monitored, controlled and registered via the SCADA system. All accessories for the proper
flow measurement will be provided.
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PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 23 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

6.3 PRIMARY TREATMENT STAGE

6.3.1 Distribution Chambers PST

Function

Distribution of the flow equally to the Primary Sedimentation Tanks (PSTs)

Explanatory Remarks

Distribution chambers of PSTs will receive the wastewater from Bypass Chamber PST and
distribute it evenly to the Primary Sedimentation Tanks.

Distribution Chambers PST will be equipped with agitator to prevent separation of sludge and
water and to guarantee equal distribution of MLSS.

After distribution, wastewater will be transferred to PSTs by pipes. Manually operated

penstocks to isolate the lines will be provided.

6.3.2 Primary Sedimentation Tank

Function

Removal of primary sludge

Main Design Data

Number of tanks 4

Diameter of tank 30 m

Water depth 3.0 m

Working volume per tank 2121 m3

Explanatory Remarks

From the Distribution Chambers PST, wastewater passes to four Primary Sedimentation
Tanks. In the PSTs, primary sludge will be separated from the wastewater by sedimentation.
Pollutant removal rates are dependent on the retention time according to ATV-DVWK-A 131E,
Table 1. Al-Khobar wastewater treatment plant primary sedimentation tank has been designed
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PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 24 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

to remove 50% of the suspended solid, 25% of organic pollutant (COD, BOD), 9.1% of nitrogen
(TKN) and 11.1% of phosphorous (P).

Four circular tanks with shield scrapers and scum removal system are foreseen. Velocities of
the inlet flow are kept slow to minimise the turbulence of the inlet. Due to the retention time
and calming down of stream, the primary sludge deposit on the bottom of the tank. Via a shield
scraper, the sludge on the bottom will be transported to the central sludge hopper of the tanks.
A pipeline connects each central sludge hopper to the primary sludge pumping station. The
sludge pumping stations will be equipped with eccentric pumps and primary sludge will be
pumped to the Sludge Mixing Tanks prior to further sludge treatments (i.e., anaerobic
digestion).

The waste water flows radially to the periphery of the primary sedimentation tanks and
discharge over a weir system to pass over into a collection channel and then into a Bypass
Collection Chamber PST from where it will gravitate to the Return Sludge Mixing Chamber.

The scum of PSTs will be collected by a surface shield scrapers scum into the collecting
chamber and pumped to the Sludge Mixing Tanks.

Primary sedimentation tanks will be fully closed with cover and collected air will be transferred
to odour treatment unit.

Local control cabinet of each primary sedimentation scraper bridge controls the system.

6.3.3 Bypass Collection Chamber PST

Function

Provide Bypass of PST (Downstream)

Explanatory Remarks

In order to achieve a maximum operation flexibility during start up and operation, primary
sedimentation tanks by-pass will be provided to be directly transferred to the Activated Sludge
Tanks. This will give more operational flexibility during operation of the plant, if its needed.
 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 25 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

6.4 BIOLOGICAL WASTEWATER TREATMENT

6.4.1 Return Sludge Mixing Chamber

Function

Receiving wastewater from PSTs, dirty filters’ backwash and return liquors, and mix with return
activated sludge.
Explanatory Remarks

This chamber will receive wastewater from PSTs, dirty filters’ backwash and return liquors, and
mix with return activated sludge. The chambers will be equipped with agitator to prevent
separation of sludge and water and to guarantee equal distribution of MLSS.
After receiving, mixed wastewater will be transferred to Distribution Chambers AST by pipes.
Manually operated penstocks to isolate the lines will be provided.

6.4.2 Distribution Chambers AST

Function

Even distribution of the flow to the Activated Sludge Tanks (ASTs)

Explanatory Remarks

These distribution chambers will receive the wastewater from Return Sludge Mixing Chamber
and distribute it evenly to the Activated Sludge Tanks. Distribution Chambers AST will be
equipped with agitators to prevent separation of sludge and water, and to guarantee equal
distribution of MLSS.

After distribution, wastewater will be transferred to ASTs by pipes. Manually controlled

penstocks to isolate the lines will be provided.

6.4.3 Activated Sludge Process

Selected activated sludge process for organic matter (organic carbon, COD, BOD5) as well as
Nutrient removal (Nitrogen and Phosphorus) is A²O process (Anaerobic, Anoxic and Oxic).
Aeration basin reactor configuration will be conventional plug-flow. Generally, pre-treated
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PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 26 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

wastewater and return activated sludge (RAS) enter the front end of the aeration tank and are
mixed by diffused air system. During the aeration period (Oxic Zone) adsorption, flocculation
and oxidation of organic matter occur. Activated-sludge solids are separated in a secondary
settling tank.

Figure 3: Schematic Diagram for A²O process

6.4.4 Anaerobic Bio-P Tanks

Function

Extended biological elimination of phosphorus

Main Design Data

Total volume of anaerobic zones 10,368 m³

Number of anaerobic zones 8

Length of anaerobic zone 18 m

Width of Anaerobic zone 12 m

Water depth of anaerobic zone 6.0 m

Explanatory Remarks

Eight anaerobic tanks will be provided. The reactor configuration utilized for phosphorus
removal is comprised of an anaerobic tank having 0.5 to 1.0 hours. The phosphorus necessary
for built-up heterotrophic biomass is calculated as 1% of inlet BOD concentration while excess
 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 27 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

biological phosphorus removal is 1.5 % of inlet BOD concentration according to ATV-DVWK-

A 131 E regulation.

In the biological removal of phosphorus, the phosphorus in the influent wastewater is

incorporated into cell biomass, which subsequently is removed from the process as a result of
sludge wasting. Phosphorus accumulating organism (PAOs) is encouraged to grow and
consume phosphorus in the system that uses a reactor configuration that provides PAOs with
a competitive advantage over other bacteria.

In order to prevent sludge sedimentation, the anaerobic tanks will be equipped with
submersible agitators.

6.4.5 Ferric Chloride Dosing Station

Function

Ferric chloride dosage for further phosphorus removal by chemical

Main Design Data

Number of Ferric Chlorine dosing tanks 2

Volume of Ferric Chlorine dosing tank 63 m3

Number of Ferric Chloride dosing pumps 3 (2 duty + 1 standby)

Capacity of Ferric Chloride dosing pump 250 L/hr at 20 mWC

Type of Ferric Chloride dosing pump membrane diaphragm dosing

Explanatory Remarks
The biological phosphorus removal process will be supported by a chemical phosphorus
removal system (FeCl3 dosing) in order to remove any excess phosphorus to meet the required
effluent discharge concentrations.
The precipitant solution will be pumped to the outlet chambers of the Activated Sludge Tanks
by means of dosing pumps. The phosphate-measurements of the outlet samples (Automatic
Samplers) are used for determination of the required amount of precipitants. The operator
calculates and provides the amount of precipitants which is required to reduce the phosphate
 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 28 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

concentration below the allowed concentration of the effluent standards and accordingly the
pumps are adjusted.
In addition, Ferric Chloride will be dosed to Sludge Mixing Tanks in order to control Struvite
(Magnesium Ammonium Phosphate (MAP)) and upstream of the Primary Sedimentation Tanks
to allow Chemically Enhanced Primary Treatment (CEPT) in case needed.

6.4.6 Activated Sludge Tank (Carbon Removal, Nitrification and Denitrification)

Function
Biological removal of organic carbon and nitrogen
Main Design Data

Total volume of denitrification zone 25,920 m³

Number of denitrification zone 8

Length of denitrification zone 45 m

Width of denitrification zone 12 m

Water depth of denitrification zone 6.0 m

Total volume of Swing zone 1,814 m³

Number of Swing zone 8

Length of Swing zone 3.15 m

Width of Swing zone 12 m

Water depth of Swing zone 6.0 m

Total volume of nitrification zone 38,707 m³

Number of nitrification zone 8

Length of nitrification zone 67.2 m

Width of nitrification zone 12 m

Water depth of nitrification zone 6.0 m

 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 29 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

Number of internal recirculation pumps 10 (8 duty + 2 store)

Capacity of internal recirculation pump 2,710 m³/hr at 0.5 mWC

Type of internal recirculation pump Propeller

Number of aeration blowers 6 (4 duty + 2 standby)

Capacity of each aeration blower 18,800 Nm³/h at 700 mbar

Type of each aeration blower Turbo blower

Explanatory Remarks
Eight activated sludge tanks are designed for organic matter (organic carbon, COD, BOD5)
removal as well as nitrification/de-nitrification (Kjeldahl-N and NO3-N) process. The tanks will
be designed as plug flow reactor with separate de-nitrification and aeration tanks and internal
circulation in order to provide the de-nitrification process.
In order to provide an operational flexibility to the biological system; part of the reactor volume
could be operable as aerobic as well as anoxic volume (swing zone). Additionally, the
anaerobic tank could be included in the volume of denitrification as the internal recirculation
pumps are designed to return the mixed liquor to both zones.
Nitrification: Conversion of ammonia into nitrite and nitrate by othotrophic bacteria via
biological oxidation.
2NH4 + 3O2 → (nitrosomonas) 2NO2 + 2H2O + 4H + new cell
2NO2 + O2 → (nitrobacter) 2NO3 + new cell

De-nitrification: Conversion of nitrate into nitrogen gas (N2) by facultative hetetrophic bacteria.
NO3 + CH3OH → 3N2 + 5CO2 + 7H2O + 6OH
The designed age of the sludge for the process will be 6 days at the minimum temperature of
20°C and the concentration of dry solids in the tank will be 3.5 kg/m3.
The de-nitrification tanks will be equipped with submersible agitators in order to ensure an
efficient mixing of sludge and water and to avoid settling of sludge in the tanks. No flow maker
or agitator will be required for aeration tank because the bottom of the aeration tank will be
covered with diffuser grit and fine bubble aeration will be sufficient to keep the biomass
suspended. The swing zone will have both agitator and fine bubble aeration.
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PROCESS DESCRIPTION

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EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 30 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

The process application will be re-denitrification with internal circulation. In this system
nitrification and carbon removal is achieved in the aeration zone, where the dissolved oxygen
concentration is maintained and de-nitrification is achieved in the anoxic zones prior to the
aeration zone. For the process efficiency considering the nitrate degradation, the activated
sludge will be recycled via internal pumps, which are located at the end of aeration zone and
the mixed liquor will be pumped back to the top of de-nitrification zone.
The applied biological wastewater treatment is based on the activated sludge process with fine
bubble aeration. For the intake of the necessary oxygen, the aeration tanks will be equipped
with fine bubble aeration, air distribution system as well as air blowers. Aeration will be
automatically regulated by electrically actuated valves based on on-line measurement of the
oxygen concentration in the individual tanks.
The blowers will be regulated with frequency controllers. Blowers will be operated
automatically based on a preset oxygen value (2 mg/l) and hence directly based on the air
pressure in the common air pressure pipe monitored in the activated sludge tanks.
Wastewater will be overflowed from each aeration basin to the outlet collecting channels. Pipes
located at the other side of collecting channel will transfer flow to Distribution Chamber SST.

6.4.7 Distribution Chamber SST

Function

Distribution of the flow equally to the Secondary Sedimentation Tanks (SSTs)

Explanatory Remarks

This distribution chamber will receive the wastewater from the outlet collection channels of
Activated Sludge Tanks and distribute it evenly to the Secondary Sedimentation Tanks.

Distribution Chamber SST will be equipped by agitator to prevent separation of sludge and
water, and to guarantee equal distribution of MLSS.

After distribution, wastewater will be transferred to SST by pipes. Manually controlled

penstocks to isolate the lines will be provided.
 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 31 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

6.4.8 Secondary Sedimentation Tank

Function

Separation of water and sludge, temporary sludge storage and sludge thickening.

Main Design Data

Number of tanks 8

Diameter of tank 40.6 m

Water depth 4.64 m

Working volume per tank 6,007 m3

Explanatory Remarks

The SSTs will be constructed as circular tanks with sloping towards hoppers located in the
centre of the tanks.

Eight circular concrete tanks with sludge scraper mechanism for the removal of sludge and
scum will be constructed.

The settled sludge is scraped into hoppers in the center of tanks by scraper blades that are
mounted to the scraper bridge. From hoppers, sludge is piped to return and surplus sludge
pumping stations by pipes.

The floating scum will be scraped by scum blades into scum collection pits and from there
scum will be pumped to the SAS Balancing Tanks.

Peripheral scum baffles and peripheral weir plates will be provided on each final clarifier to be
retained within the process stream. The weir plate will utilize V notch design and shall be sized
to accommodate the maximum flow rate without overtopping.
 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 32 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

6.5 TERTIARY TREATMENT

6.5.1 Filter Station

Function

Further removal of solids in treated wastewater

Main Design Data

Number of filters 8 (6 duty + 2 standby)

Capacity of each filter 2,242 m³/hr

Design Inlet Total Suspended Solids 20 mg/L

Required Outlet Total Suspended Solids 10 mg/L

Explanatory Remarks

Tertiary filtration will be designed to receive secondary effluent and to allow effective polishing
of the secondary effluent to achieve TSS effluent values of < 10 mg/L. Filtered water will be
conveyed to tertiary disinfection/Chlorine Contact Tanks via pipes. Captured solids, contained
in the filter backwash water, will be returned to the Return Sludge Mixing Chamber.

The whole Filter Station will consist of 8 filter units each located in a separate filter chamber (2
units will be standby).

The backwash water will be collected in the central backwash water channel from where it
gravitates to the Dirty Backwash Pumping Station.

The Disc Filter works on the basis of the well-proven drum filter principle. The screen consists
of horizontally arranged rotating filter discs installed on a central hollow shaft. The wastewater
to be treated enters the Disk Filter a rectangular inlet box and then flows via the central hollow
shaft into the individual disc segments. The solids are kept on the inside of the disc while the
clear filtrate passes through the mesh into the tank from where it discharges via an overflow
weir at the end of the tank.

The filter discs remain in rest position during the filtration process which is a continuous
process. The (suspended) solids settle by gravity on the inner disc surface, which leads to
gradual blinding of the filter mesh with the retained solids as the filtration process progresses,
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PROCESS DESCRIPTION

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EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 33 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

resulting in an increases pressure difference between the flow inside the disc towards the clear
water level in the tank. When the predefined maximum internal pressure difference of typical
100 mm has been reached, the solids are removed from the filter surfaces by a slow rotation
of the filter discs combined with a backwash of the filter mesh. The backwash pumps feeding
the spray bar / nozzles are an integral part of the Disk Filter unit and do use the filtered water
from the tank. The backwash process goes on until the pressure difference has dropped again.

The removed solids are washed into a trough situated below the segment openings prior to
being drained off. The filtration process runs on continuously whilst the filter discs are being
cleaned.

6.5.2 Dirty Backwash Pumping Station

Function

Transferring of dirty backwash water to Return Sludge Mixing Chamber.

Main Design Data

Number of backwash pumps 3 (2 duty + 1 standby)

Capacity of drain pumps 170 m³/hr at 15 mWC

Type of drain pumps centrifugal (submersible)

Explanatory Remarks

There will be three submersible pumps (2 duty and 1 standby) of the same size installed within
the dirty backwash pumping station. They will have the task to forward the collected dirty
backwash which is produced by the filter station to the Return Sludge Mixing Chamber.

The duty backwash pumps will be switched on and off by a level sensor which is installed
within the dirty backwash pumping station, which will be also used for prevention overfilling
and dry running protection.
 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 34 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

6.5.3 Effluent Flow Measurement

Function

Determination of the outlet effluent treated sewage flowrate

Explanatory Remarks

Effluent treated sewage flowrate will be measured by means of two electromagnetic flow
meters, monitored, controlled and registered via the SCADA system. All accessories for the
proper flow measurement will be provided.

6.5.4 NaOCl Generation Plant (Disinfection)

Function

On site generation of Sodium Hypochlorite (NaOCl) solution from Sodium Chloride (NaCl) and
potable water
Main Design Data

Number of NaOCl Generator – new Expansion Al Khobar STP 4 (3 duty + 1

standby)

Capacity of each NaOCl Generator - new Expansion Al Khobar STP 45 kg Cl2/h

Number of NaOCl dosing tanks - new Expansion Al Khobar STP 4

Volume of each NaOCl dosing tank - new Expansion Al Khobar STP 32 m3

Number of NaOCl dosing pumps - new Expansion Al Khobar STP 3 (2 duty + 1

standby)

Capacity of each NaOCl dosing pump - new Expansion Al Khobar STP 7 m3/hr at 20 mWC

Type of NaOCl dosing pump - new Expansion Al Khobar STP Eccentric screw

Number of NaOCl Generator - Existing Al Khobar STP 4 (3 duty + 1

standby)

Capacity of each NaOCl Generator - Existing Al Khobar STP 20 kg Cl2/h

Number of NaOCl dosing tanks - Existing Al Khobar STP 4

 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 35 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

Volume of each NaOCl dosing tank - Existing Al Khobar STP 20 m3

Number of NaOCl dosing pumps - Existing Al Khobar STP 3 (2 duty + 1

standby)

Capacity of each NaOCl dosing pump - Existing Al Khobar STP 3.5 m3/hr at 20
mWC

Type of NaOCl dosing pump - Existing Al Khobar STP Eccentric screw

Explanatory Remarks

Complete disinfection plants will be provided for both new expansion of Al Khobar plant and
also for existing Al Khobar plant to inactivate pathogens in the treated effluent and to provide
a residual chlorine concentration in the treated effluent. Disinfection will be affected by a
sodium hypochlorite (NaOCl) solution generated on site from sodium chloride (NaCl) and
potable water by adopting an electrolysis process.

In the new expansion of Al Khobar STP, the dosing points for the effluent disinfection will be
situated in the Chlorine Contact Tank feed pipes. The Disinfection facility will be designed to
be capable to provide a continuous dosage of NaOCl solution into the effluent of 8 mgCl2/L.
The two dosing points downstream of the filter station will be served by a pump set operating
in a 2+1 operation mode. The chlorine dosing rate will automatically be adjusted proportionally
to the plant inflow (feed forward control) supported by residual chlorine measurements at the
outlet of the Chlorine Contact Tank.

6.5.5 Chlorine Contact Tank

Function

To allow a complete reaction of chlorine upstream of the effluent measuring point

Main Design Data

Total volume of Chlorine Contact Tanks 6,776 m³

Number of Chlorine Contact Tank 2

Length of Chlorine Contact Tank 44 m

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EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 36 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

Width of Chlorine Contact Tank 22 m

Water depth Chlorine Contact Tank 3.5 m

Retention time at peak flow 30 minutes

Explanatory Remarks

In order to allow a complete reaction of chlorine upstream of the effluent measuring point,
Chlorine Contact Tanks will to be provided. The tanks will be made of concrete and will be
completely covered. The Chlorine Contact Tanks will be equipped with sufficient flow baffles
in order to guarantee a proper plug flow pattern.

The effluent sampling point for the automatic sampling device and the online monitoring for the
parameter residual chlorine, pH and turbidity will be located in the outlet chamber of the
Chlorine Contact Tanks.

Service water will be withdrawn from the tank outlet shaft by means of pipes.

6.5.6 Outlet Quality Measurement

Function
Sampling of the effluent wastewater
Explanatory Remarks
Two automatic samplers will be installed in the outlet chambers of the Chlorine Contact Tanks
to collect and store water samples from the effluent. Effluent quality control for pH value,
conductivity and temperature will be also located in each outlet chamber. The automatic
samplers can take flow proportional 24-hour-composite samples. All the necessary
equipment will be provided.

6.5.7 Service Water Pumping Station

Function

Usage of treated effluent for Screening Building, Sludge Thickening & Dewatering Building,
Odour Control Units and other consumers.
 Document Title:
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Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 37 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

Main Design Data

Number of service water pumps: 3 (2 duty + 1 standby)

Capacity of service water pump: 100 m3/hr at 70 mWC

Type of service water pump: Centrifugal (dry mounted)

Explanatory Remarks

For the service water supply, service water will be withdrawn from the outlet chamber of the
Chlorine Contact Tanks by means of pipes.

A compressed air reservoir tank, which will reduce the number of operations of these pumps,
is included within the Service Water Pumping Station.

The demand for service water will mainly be in the screening plant (screenings wash press,
grit classifiers), sludge thickening and dewatering building and odour control units.

The cut in and cut out of the service water pumps will be controlled by pressure measurement
on the pumping main.

6.5.8 Treated Effluent Storage Tank

Function

Storage of the treated effluent

Main Design Data

Total volume of Treated Effluent Storage Tanks 12,004 m³

Number of Treated Effluent Storage Tank 2

Length of Treated Effluent Storage Tank 76.7 m

Width of Treated Effluent Storage Tank 31.3 m

Water depth Treated Effluent Storage Tank 2.5 m

 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 38 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

Explanatory Remarks

Treated effluent from Chlorine Contact Tanks will gravitate to Treated Effluent Storage Tanks,
which will be completely covered and equipped with an outlet overflow for the discharge of
treated water.

Discharged treated effluent will be via an overflow to a chamber, which will be connected to
the existing Irrigation Pumping Station (main consumer of treated effluent). In case of excess
treated effluent, it will overflow to the new Sea Outfall Pumping Station for discharge to the
sea.

6.5.9 Sea Outfall Pumping Station and Pipeline

Function

Discharge of treated wastewater to the sea.

Main Design Data

Number of sea outfall pumps: 8 (6 duty + 2 standby)

Capacity of sea outfall pump 5000 m3/hr at 10 mWC

Type of sea outfall pump Centrifugal

Explanatory Remarks

Sea outfall pumps and pipeline will be provided in order to pump excess treated wastewater
into the Gulf.

This new pumping station will serve also other existing plants e.g., Khobar STP and Ajyal STP
as well as the new expansion of Al Khobar STP.
 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 39 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

6.6 SLUDGE TREATMENT

6.6.1 Primary Sludge & Scum Pumping Stations

Function
Pumping the primary sludge and scum to Sludge Mixing Tank
Main Design Data

Number of primary sludge pumps 6 (4 duty + 2 standby)

Capacity of primary sludge pumps 15 m³/hr at 25 mWC

Type of primary sludge pumps Eccentric screw

Number of primary scum pumps 4 (2 duty + 2 standby)

Capacity of primary scum pumps 10 m³/hr at 25 mWC

Type of primary scum pumps Eccentric screw

Explanatory Remarks
Sex progressive cavity pumps (two as stand by) will pump primary sludge in to sludge mixing
tanks. Two electromagnetic flow measurements will be provided on discharge line of primary
sludge pumps to measure the quantity of the primary sludge.
The scum that is taken from the primary sedimentation tanks will be transferred from scum
collection chambers to Sludge Mixing Tanks by PST scum pumps (2 duty + 2 standby).
The primary sludge pumps operate in time intervals (Control by timer and flow meter on the
pumping main) throughout the day depending on the dynamic solids load to the STP and
depending on the sludge concentration which is required to be achieved.

6.6.2 Return & Surplus Sludge and Secondary Scum Pumping Stations
Function
Pumping of return sludge to the Return Sludge Mixing Chamber and pumping of surplus
activated sludge and secondary scum to the SAS Balancing Tanks
Main Design Data
 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 40 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

Number of return sludge pumps 12 (10 duty + 2 standby)

Capacity of return sludge pumps 1,100m³/hr at 4.6 mWC

Type of return pumps Centrifugal (submersible)

Number of surplus sludge pumps 4 (2 duty + 2 standby)

Capacity of surplus sludge pumps 155 m³/hr at 15 mWC

Type of surplus pumps Centrifugal (submersible)

Number of secondary scum pumps 4 (2 duty + 2 standby)

Capacity of secondary scum pumps 10 m³/hr at 15 mWC

Type of secondary scum pumps Eccentric screw

Explanatory Remarks

Sludge collected from the Secondary Sedimentation Tanks flows via pipes to the RAS/SAS
pumping station by gravity.
Each pipeline enters the return sludge pumping station through separate reservoirs and the
inlet flow to the pump’s sump is controlled by adjustable motorized weir penstocks. Controlling
of the opening/ closing of these penstocks is provided via ultrasonic flow measurements that
are placed in the inlet reservoirs of the pump sump. According to the signals from plant’s inlet
flow measurement and selected rate of recirculation, ultrasonic flow measurements supervise
the adjustable motorized weir penstocks.
Operation of RAS pumps will be controlled by ultrasonic level measurement instruments in the
pump sumps, which also provide protection of the pumps from dry running.
Submersible pumps will be provided for pumping the surplus activated sludge to SAS
Balancing Tank. The SAS pumps shall be fixed-speed and shall operate until a set daily volume
is pumped out in order to maintain the design sludge age. A flowmeter is installed on the
discharge pipe of the WAS pumps for this purpose.
The SST scum that is taken from the SSTs is transferred from scum pits to SAS Balancing
Tanks by progress cavity SST scum pumps (2 duty + 2 standby).
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PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 41 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

6.6.3 SAS Balancing Tanks

Function

Collection and Storage of surplus activated sludge and SST scums

Main Design Data

Total volume of SAS balancing tanks 616 m³

Number of SAS balancing tank 2

Length of SAS balancing tank 11 m

Width of SAS balancing tank 5m

Sludge depth of SAS balancing tank 5.6 m

Explanatory Remarks

Surplus sludge will be pumped to SAS Balancing Tanks in order to store and homogenize the
surplus sludge before thickening. Furthermore, scum from the secondary sedimentation tanks
will be pumped into the SAS Balancing Tanks as well.
The tanks will be equipped with submersible agitators in order to ensure an efficient mixing
and to avoid settling of sludge in the tanks. Also, level in the tanks will be measured to control
the pumps and mixers.

The tanks will be covered with GRP and forced ventilated. The extracted foul air will be treated
by the odour control unit.

6.6.4 Mechanical Sludge Thickening Plant

Function

Volume reduction of surplus activated sludge

Main Design Data

Number of thickener feed pumps 4 (3 duty +1 standby)

Capacity of thickener feed pumps 105 m³/hr at 10 mWC

 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 42 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

Type of thickener feed Eccentric screw

Number of mechanical thickeners 4 (3 duty +1 standby)

Capacity of mechanical thickener 105 m³/hr at DS = 0.8 %

Type of mechanical thickener Belt thickener

Number of polymer preparation units 1

Capacity of polymer preparation unit 9.91 kg/hr polymer (1982 l/hr @ 0.5%)

Number of polymer dosing pumps 4 (3 duty +1 standby)

Capacity of polymer dosing pumps 700 L/hr at 20 mWC

Type of polymer dosing pumps Eccentric screw

Number of thickened sludge pumps 4 (3 duty +1 standby)

Capacity of thickened sludge pumps 15 m³/hr at 30 mWC

Type of thickened sludge Eccentric screw

Explanatory Remarks
Surplus sludge and scum from secondary sedimentation tanks will be mechanically thickened
by means of four mechanical thickeners (one as standby). For this purpose, the sludge will be
delivered by four feed pumps (one as standby) to the belt thickeners.
Belt thickeners are continuous gravity filters with a screening belt which runs between two
rollers and onto which the sludge to be thickened is fed. Filtrate of the thickening process will
flow to the Return Liquor Pumping Station via gravity pipe line. Thickened sludge flows into the
suction line of the thickened sludge pumps, which pump direct the thickened sludge to the
Sludge Mixing Tanks.

In order to improve the sludge characteristic regarding to its thickening capability, it is planned
to apply coagulant aids (polymers) to the thin sludge directly. The sludge will be thickened up
to about up to 6 % DS and one polymer preparation & dosing station will be installed which
serves for pre-conditioning of the thin sludge prior to the four belt thickeners. Four frequency
converter controlled positive displacement pumps will be used for polymer dosing and each
pump will be associated with one belt thickener. The polymer preparation plant will be a
package plant coming with its own local control cabinet.
 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 43 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

The belt thickeners will be fully closed for the provision of odour control and extracted foul air
will be transferred into the odour treatment unit. The start and stop signal of the thickening
machine will be given manually by the operator via HMIs, after that the machines will be
operated in full automation.

Thickening units, polymer preparation & dosing station and all relevant equipment will be
located in Sludge Thickening & Dewatering Building.

6.6.5 Sludge Mixing Tanks

Function

Storage and mixing of SAS and SST scum (after thickening) with the primary sludge and scum

Main Design Data

Total volume of sludge mixing tanks 906 m³

Number of sludge mixing tanks 2

Length of sludge mixing tank 11 m

Width of sludge mixing tank 7.35 m

Sludge depth of sludge mixing tank 5.6 m

Explanatory Remarks

Sludge Mixing Tanks will be provided to store thickened surplus sludge & SST scum and
primary sludge & PTS scum prior to feed to the anaerobic digesters. Tanks will be equipped
with agitators. Also, level measurements will be provided for control purposes.

The tanks will be equipped with submersible agitators in order to ensure an efficient mixing
and to avoid settling of sludge in the tanks. Also, level in the tanks will be measured to control
the pumps and mixers.

The tanks will be covered with GRP and forced ventilated. The extracted foul air will be treated
by the odour control unit.
 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 44 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

6.6.6 Digester Feed Pumping Station

Function
Pumping the mixed sludge to the anaerobic digesters
Main Design Data

Number of digester feed pumps 6 (4 duty +2 standby)

Capacity of digester feed pumps 21 m³/hr at 40 mWC

Type of digester feed pumps Eccentric screw

Explanatory Remarks

Mixed sludge will be pumped to the anaerobic digesters with six eccentric screw pumps (two
as standby). For each two digesters, two duty eccentric screw pumps will be provided as
digester feed pumps and one common standby pump. Each digester feed line will be equipped
with an electromagnetic flow meter to monitor the flowrate inlet to digesters.

Sludge feeding to the digesters will be started and stopped by the level measurement within
the Sludge Mixing Tanks. One adjustable feeding timer controls whether digesters will be fed
or not. Therefore, the duration for sludge feeding will be set by the operator. Several interlocks
will be existed for the feeding pumps such as level measurements in the Sludge Mixing Tanks
& Digesters, sludge re-circulation pumps, heating system, etc.

6.6.7 Anaerobic Sludge Digestion

6.6.7.1 Introduction
Anaerobic sludge digestion was developed decades ago and today is an integral part of most
sophisticated disposal concepts. ARTELIA has experience
with more than 1,500 sludge digesters worldwide and is a leader in the design and optimization
of this process. In fact, the anaerobic sludge digestion process was meanly developed in our
company (former “Roediger – Anlagenbau”) and the well-known manual guide for sludge
digestion which is an essential work book for experts for waste water treatment plants was
written by us. So our company has an experience of more than 74 years in design, build,
commissioning and operation of digestion plants.
 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 45 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

In view of the above, ARTELIA would like to incorporate its obtained expertise from the
supply, installation, commissioning and maintenance of more than 1,500 plants worldwide into
the design of Expansion of Al Khobar STP:

• The offered Equipment has been successfully implemented around the globe.

• Installation will be supervised by our own highly experienced personnel.

The sludge digestion system will consist of four mesophile anaerobic digesters with associated
mixing, heating and biogas storage & utilisation equipment. The digestion system is based on
ARTELIA’s established processes and wealth of experience gained from many installations
worldwide.

Below digester’s equipment are produced by ARTELIA as licensed professional firm

according to DVGW G 301 (Rules of the German Technical and Scientific Association for Gas
and Water).

DIGESTION EQUIPMENT

1 Manhole

2 Heat Exchanger

3 Seeding Mixer

4 Scum Removal

5 Recirculation Pumps

6 Scum-Breaker

7 Gas Hood

8/9 ARTELIA Gas Injection

System

10 Gravel Filter

11 Ceramic Filter

12 Condensate Drain

13A Gas flare

13B Concealed Burning

14 Height Adjustable Sludge

Discharge

15 Supernatant Discharge

16 Boiler

17 Gas Storage

Figure 4: ARTELIA’s Digester Equipment

 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 46 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

6.6.7.2 Digester Tanks and Feeding & Heating

Main Design Data

Number of digester tanks 4

Diameter of digester tank 20 m

Sludge height 23.5 m

Working volume per digester tank 6,900 m3

Number of Inline mixers 4

Capacity of Inline mixer Raw sludge capacity: 21 m3/h

Recirculation sludge capacity: 110 m3/hr

Number of digester recirculation pumps 8 (4 duty + 4 standby)

Capacity of digester recirculation pumps 110 m³/hr at 5 mWC

Type of digester recirculation pumps Dry Installed Centrifugal

Number of digester heat exchangers 4

Capacity of digester heat exchangers 609 kW

Type of digester heat exchangers Pipe in pipe heat exchange

Explanatory Remarks
The mixed thickened sludge from the Sludge Mixing Tanks will be pumped to the inject points
of the heating exchanger prior to the digester.

In the inoculation mixer the sludge is mixed together with the recirculation sludge, so that
seeding with the recirculation sludge, which is already undergoing digestion, as well as pre-
heating, is achieved at the same time.

The raw sludge and seeding sludge are transported from the inoculation mixer via the heat
exchangers, construction by ARTELIA, where the sludge is indirectly heated counter
currently by heating water. The heated sludge mixture is transported via the feeding line into
the digester.
 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 47 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

During the feeding process with raw sludge, digested sludge from the hopper is displaced via
the rising pipeline by the discharge device. Digested sludge is discharged in a separate outside
shaft and from there digested sludge flows to the Digested Sludge Storage Tanks.

Digester Recirculation Pumps switched on and off by digester feed pumps operation or by heat
demand (temperature measurement within digesters).

6.6.7.3 Digester Mixing (Injection System)

Main Design Data

Number of hanging gas lances 48 (12 for each digestor)

Capacity of each hanging lance 60 Nm³/h

Number of ceramic filters (Gas Lance Mixing) 4

Capacity of ceramic filters (Gas Lance Mixing) 240 Nm3/h

Number of gas compressors (Gas Lance Mixing) 4

Capacity of gas compressors (Gas Lance Mixing) 240 Nm3/h at 2.5 bar

Explanatory Remarks
The gas injection serves for intensified re-circulation of the digester contents. The system is
patented for ARTELIA (CH - Pat. Nr. 671 885). There are 12
hanging lances in each digester, the distributors of which are arranged at a low level above
the bottom of the digester. The lances are operated according to a special scheme in order to
achieve an optimal mixing of the raw sludge into the digester content. The digester gas is taken
out of the digester hood, construction by ARTELIA and is discharged into a separate
circulation. At first the gas is sucked via the suction line out of the digester, then it flows through
a ceramic filter (constructed by ARTELIA) which serves for pre -filtering, then it is
compressed in the gas compressor. The compressed gas from the gas compressor is delivered
via a liquid separator and the pressure line to the gas lances. The gas injection can be affected
automatically.

The gas injection System ARTELIA uses special inje ction heads
which hang at flexible special hoses (lances); the system is conceived in a manner that no
sludge can penetrate into the gas lines when the gas compressors are cut off and that the
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PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 48 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

lances can be pulled out of the digester without interruption of the operation of the digester. By
the utilization of special gas compressors for the compression of the gas damages because of
corrosion are prevented. Besides, all parts coming into contact with the gas are made of special
alloys.

Digester mixing system is a timer-controlled system with mixing time and break time for the
various segments of the digester.

6.6.7.4 Scum Removal

Explanatory Remarks
At the surface of the digesters accumulation of light floating substances may occur, which tend
to felting and form a compact floating layer (scum). If scum, however has accumulated, it
should be discharged in regular intervals via the scum doors into shaft at the digester hood
(constructed by ARTELIA) and should be removed out of the digester. This will happen
when the sludge level is banked a little bit, the door is unlocked and opened, so that the scum
is flushed out in a gush. The doors are entirely gas-tight and constructed in a manner that they
can be easily and fast opened and closed; a patented lock prevents an opening of the doors
by the gas pressure in the digester.

6.6.7.5 Digester Gas Production and Gas System

Explanatory Remarks
During the degradation of the organic dry solids by the anaerobic digestion, biogas is produced
as one of the products of this biochemical process. This biogas is a mixture of about 2/3
methane and 1/3 carbon dioxide having an average calorific value of about 5,590 kcal/Nm³
(about 6.4 kWh/Nm³) in general. The specific gas production is dependent on the origin and
the composition of the sludge. The specific gas production for municipal sewage sludge is in
this case about 0.8 Nm³ per 1 kg degraded organic dry solid. The capacity of the gas devices
and also of the gas lines is dimensioned considering the peak factor in the gas production, in
order to avoid overcharge of the devices pressure losses in the lines.

In order to protect the digester against an over-pressure (over 0.05 bar = 500 kp/m³) or sub-
pressure a special combined protection device for gas over-pressure and sub-pressure
(constructed by ARTELIA), is installed in the gas hood with a hydraulic seal. The
construction of the device is made in such manner that the sealing liquid (usually water) does
 Document Title:
PROCESS DESCRIPTION

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EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 49 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

not run out of the device. When the original conditions are restored, the sealing liquid flows
back again. In case of very strong pressure blasts, smaller loss of sealing liquids is possible.
Therefore, the device is equipped with a level indicator which has to be checked daily. Since
the device is immerged in the digester roof (in the gas room) and is continuously heated by the
temperature being present in this area, there is no danger of freezing.

Further, a gas-tight and swivelling observation window (constructed by ARTELIA) is

installed in the gas hood. It serves at the same time as access opening. The window has on
both sides’ wipers for removal of the condensation water. It is protected against damage by a
tip-up cover. At the same time this cover keeps away light beams, which are not desired by
the organisms in the digester.

There is a gas withdrawal dome (constructed by ARTELIA) installed on the gas hood,
which serves for the withdrawal of the biogas for the further utilisation. The gas dome is
equipped with a foam trap. This foam trap shall prevent the penetration of the foam into the
gas system.

6.6.7.6 Measurement and Process Control Equipment

Explanatory Remarks
According to numerous experiences, a continuous process monitoring is essential for the
control of the sludge digestion process. This control and the monitoring are taken for both
sludge and biogas.

Monitoring and control of sludge process:

• Monitoring and control of the digester contents (level measurement). The measurement
according to the hydrostatic pressure principle by pressure sensors.

• Monitoring and control of the temperature of the digester at three measurement points
in each digester.

• Monitoring and control of the pH-value of the fresh feed sludge. A measurement point
is located at the circulation-pipe line. The electrode takes continuously the pH-value
and gives it to the indication instrument. Therewith the pH-value of the sludge is
controlled in the digester.
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EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 50 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

Monitoring and control of gas process:

• Monitoring and control of the gas production with one measurement point in the main
line. The entire gas unit is continuously measured via an orifice gauge, indication and
addition is made.

• Monitoring and control of the gasometer level. This measurement point is located at
the gasholder and is showing the actual level and also some contacts with which the
flare is switched on and off, resp. alarm is taken off or release statement for the heating
boiler or the power plant is given. Since the gasometer has an optic indication, this
measuring point is connected to the mechanic indication instrument.

• Flow Measurement of utilisation gas with each measurement point in front of boiler and
of gas engine.

6.6.8 Gas Utilisation Plant

6.6.8.1 Biogas Pre-Treatment

Function

Pre-dewatering and pre-filtering of the biogas

Main Design Data

Number of gravel filters 1

Capacity of gravel filters 800 Nm3/h

Explanatory Remarks

The biogas is withdrawn via the gas withdrawal dome out of the head of the digester with a
pipeline. The gas flows into the gravel filter (constructed by ARTELIA) which serves for the
pre-dewatering and pre-filtering (coarse filtering) of the biogas. The condense water is
separated at the surface of the filling material (gravel) and is collected on the bottom of the
filter. There it is discharged via a siphon.
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EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 51 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

6.6.8.2 Biogas Desulphurization

Function

Reduction of hydrogen sulfide amount of the biogas

Main Design Data

Number of desulphurization units 1

Capacity of desulphurization unit 800 Nm3/h

Type of desulphurization unit Biological

Explanatory Remarks

After gravel filter, biogas will flow to desulphurization plant for further treatment. The purpose
of the plant is to reduce the amount of hydrogen sulphide of the biogas. The removal of the
Sulphur in the biogas is done with the help of Bacteria. The desulphurization plant is package
unit and controlled by its own control panel. The sulphate waste stream produced at the
Desulphurisation Unit is discharged to the Return Liquor Pumping Station.

6.6.8.3 Gas Holder

Function

Storage of produced biogas

Main Design Data

Number of Gas Holders 2

Type Double-Membrane

Volume 4,500 m3

Storage capacity 12 hours

Explanatory Remarks

Gas line goes to the low-pressure gasholders with a usable volume of 4500 m³. These gas
meters serve for storage and pressure compensation resp. pressure maintenance in the gas
system and will be designed for a storage capacity of about 12-hour production.
 Document Title:
PROCESS DESCRIPTION

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EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 52 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

After the desulphurization plant, the biogas flows to two low pressure gasholders (tanks). The
gas production by the anaerobic sludge digestion is not constant during the whole day. There
is a peak gas production expected especially after the feeding of the digester with raw sludge.
The task of the gas holder is to store intermediately the peak gas production during the day so
that the biogas consumers e.g., Combined Heat & Power (CHP) units or boiler can be fed with
biogas also in times when the biogas production is low.

Each Gasholder consists of a double Membrane. Air is blown into between the two membranes
through the blowers. This creates the pressure in the Biogas System. The gasholders are
directly integrated in the main gas pipe. There will be an automatic condensate trap installed
prior to and right after each gas tank. These condensate traps are placed in a small chamber
directly at the gas tanks. The removed and collected condensate flows into a pump sump which
is equipped with a condensate pump.

The gas holders will be equipped with level measurements. This is required for the control of
the gas holders, gas flare, gas boiler as well as CHP units. Therefore, several pre-set values
have to be created and adjusted to ensure a proper operation of the gas utilization plant.

6.6.8.4 Biogas Flare

Function

Burning of excess biogas

Main Design Data

Number of Biogas Flare 1

Type of Biogas Flare Vertical Steel Tube

Capacity of Biogas Flare 800 Nm3/h

Explanatory Remarks

If the gasholder is filled up to a maximum level, a certain quantity of the gas is burnt off
automatically by a gas flare which is connected with the gas system via a branch line (through
Biogas Booster Blowers). The control of the gas flare and the protection is fully automatic in
dependence on the level of the gasholder (the gas flare is switched on and off by the level
measurement within gas storage tank (e.g. high-high level))
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EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 53 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

6.6.8.5 Biogas Filters

Function

Fine-purification of the biogas and removal of Siloxane

Main Design Data

Number of ceramic filters 1

Capacity of ceramic filters 800 Nm3/h

Number of siloxane filters 1

Capacity of siloxane filters 800 Nm3/h

Explanatory Remarks

The biogas used in the CHP units and/or dual fuel burner flows to the gas filtering devices.
This plant consists of a ceramic filter (constructed by ARTELIA), which serve for fine -
purification; in these filters a number of fine-pored filter candles is arranged, through which the
gas is flowing from the inside to the outside. During this process fine polluted matter and the
remaining moisture is filtered out of the gas and fall from the outside of the filter candles into
the collection chamber of the filter, while the purified gas is flowing on to the biogas consumers.

In addition, prior to the biogas consumers, the biogas will pass through Siloxane removal
system (using granular activated carbon filters) in order to remove the undesirable silicon
components.

6.6.8.6 Biogas Booster Blowers

Function

Boosting biogas pressure to the required level by the consumers

Main Parameters

Number of booster blowers 3 (2 duty + 1 standby)

Capacity of booster blower 400 Nm3/h at 100 mbar

 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 54 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

Explanatory Remarks

Stored biogas in the gasholders doesn’t have enough pressure to flow to the consumers i.e.,
CHPs and/or boiler, therefore, booster blowers will be provided to increase pressure of biogas
upto required level for the final consumers as recommended by the manufacturers. The
blowers will have variable speed and will be controlled based on the level of the gasholders
(switch-off function for Biogas booster blowers will be provided in dependence with the filling
level of the gas holders and operation command of the consumers (i.e. CHPs, and/or boiler)).

6.6.8.7 Biogas Consumers (CHP and Dual Fuel Boiler)

Function

Generation of electricity and heat from biogas

Main Design Data

Number of CHP units 4

Type of CHP units Combined Heat and Power Generating

Engine

Capacity of CHP unit Electrical: 473 kW, Heat: 494 kW

Number of Gas Boilers 1

Type of Gas Boiler Dual Fuel (Biogas & Liquid Fuel)

Capacity of Gas Boiler 1700 kW

Explanatory Remarks

CHP-units are installed for energy recovery purposes. The power plant consists of combined
heat and power units. It is heated with combined full automatic digester gas excess pressure
burners. The burner is equipped with special safety and regulation armatures. The heated
water flows through the lines from the boilers to the distributor battery. Heating circulating
pumps deliver a part of this water to the heat exchangers, construction (constructed by
ARTELIA . Power is produced when the digester gas is burnt and
the waste heat from cooling and waste gas is used for heating of water. The water has normally
a temperature of 70°C when it is used for the motor and is heated up to 90°C. The hot water
is delivered over the heat distributors to the heating circuit.
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EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 55 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

Produced biogas will be primarily utilized in four CHP units to produce required head demand
in the plant and production of electricity. Furthermore, a dual fuel boiler that has capacity of
plant’s head demand will be provided to be used for the start-up period when produced biogas
is insufficient and also as back-up when the CHP unit is not in operation.

The CHP units will be installed for energy recovery purposes. The power plant consists of
combined heat and power units. It is heated with combined fully automatic digester gas excess
pressure burners. The burner is equipped with special safety and regulation armatures.
Heating circulating pumps deliver a part of this water to the heat exchangers. Power is
produced when the digester gas is burnt and the waste heat from cooling and waste gas is
used for heating of water. The water has normally a temperature of 70°C when it is used for
the motor and is heated up to 90°C. The hot water is delivered over the heat distributor to the
heating circuit.

For start-up of operation and emergency cases, sufficient boiler capacity will be provided. The
boiler will be of the dual fuel type capable to be operated whether with biogas or light fuel oil.

Biogas Consumers (CHP and Dual Fuel Boiler) will be switched on and off by level
measurement within gas storage tank according to the heat demand by the plant.

Gas rooms, heating room and CHP room will be provided with emergency fans. The fans will
switch on automatically when the gas detectors indicate a high gas level within above
mentioned rooms.

6.6.9 Digested Sludge Storage Tanks

Function

Storage of digested sludge

Main Design Data

Number of tanks 2

Diameter of tank 20 m

Sludge depth 6.56 m

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EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 56 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

Working volume per tank 2,061 m3

Explanatory Remarks

There will be two storage tanks for digested sludge from anaerobic digestion process. The
tanks will be circular and equipped with submersible mixers for avoiding sedimentation of
sludge, as well as level measurements for monitoring and controlling the dewatering feed
pumps. The task of the Digested Sludge Storage Tanks is to store the digested sludge prior to
the sludge dewatering plant. The tanks will be covered with GRP and forced ventilated. The
extracted foul air will be treated by the odour control unit.

The mixers will operate with the operation of dewatering plant (centrifuges), when the
centrifuges are not in operation, then mixer’s control will be a timer (operation/break timer).

6.6.10 Dewatering Feed Pumping Station

Function

Pumping the digested sludge to dewatering machines

Main Design Data

Number of dewatering feed pumps 4 (3 duty +1 standby)

Capacity of thickener feed pumps 30 m³/hr at 20 mWC

Type of thickener feed Eccentric screw

Explanatory Remarks
Digested sludge will be pumped to the dewatering machines via eccentric screw pumps with
frequency convertors. An electromagnetic flow measurement will be provided at the discharge
lines of the dewatering feed pumps to measure its quantity.

For control purpose there will be installed level measurements within each Digested Sludge
Storage Tanks, which will be also used for dry-run protection of the pumps.

Starting and stopping of each dewatering feed pump will be done in accordance with the
command signal received from control panel of corresponding dewatering machine (i.e.,
centrifuge).
 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 57 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

6.6.11 Sludge Dewatering Plant

Function

Dewatering of digested sludge

Main Design Data

Number of dewatering machines 4 (3 duty +1 standby)

Capacity of mechanical thickener 30 m³/hr at DS = 3.39 %

Type of mechanical dewatering Centrifuge

Number of polymer preparation units 1

Capacity of polymer preparation unit 21.35 kg/hr polymer (4271 l/hr @ 0.5%)

Number of polymer dosing pumps 4 (3 duty + 1 standby)

Capacity of polymer dosing pumps 1500 L/hr at 20 mWC

Type of polymer dosing pumps Eccentric screw

Explanatory Remarks

Digested sludge from the Digested Sludge Storage Tank will be pumped by sludge dewatering
feed pumps to four Centrifuges (one as standby) in order to reduce the amount of sludge. The
dewatered sludge will contain approx. 22% solid substances.

Before the entering of the sludge to the Centrifuges, polymer is dosed into the feeding pipe in
order to condition the sludge accordingly. The polymer preparation unit will allow the use of
polymers in both granular and liquid form. The polymer preparation units prepare 0.5% solution
with potable water. The 0.5% solution is then post diluted with service water to 0.1% solution
prior to mixing with sludge, to improve blending and flocculation. Diluted polymer will be dosed
by four (one pump for each line) frequency-controlled eccentric screw pumps before the
Centrifuges. The polymer preparation unit will be a stand-alone unit and will be automatically
controlled locally by a local control panel. The flow on the polymer line will be measured with
electromagnetic flow meter.

The designed load conditions will be daily operating period of 16 hours and 7 days a week.
The filtrate from the Centrifuges will flow by gravity to the Returns Liquor Pumping Station
 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 58 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

where it will be pumped back to the plant. Dewatered sludge will be taken into the conveyor
and transferred to sludge cake storage area. Dewatering units, polymer preparation and dosing
station and all relevant equipment will be located in Sludge Thickening & Dewatering Building.
A crane will be provided to the building in case any maintenance requirement is occurred.

The sludge dewatering machines and the polymer preparation and dosing plant are package
units coming with their own local control panels.

6.6.12 Sludge Storage Area

Function

Storage of stabilized and dewatered sludge

Explanatory Remarks

After the solids content in the sludge is increased to 22%, stabilized and dewatered sludge will
be transported to the Sludge Storage Area for an intermediate storage.

6.6.13 Returns Liquor Pumping Station

Function

Transferring return liquors/supernatant and drainage to Return Sludge Mixing Chamber

Main Design Data

Number of returns liquor pumps 3 (2 duty + 1 standby)

Capacity of returns liquor pumps 190 m³/hr at 15 mWC

Type of returns liquor pumps Centrifugal (submersible)

Explanatory Remarks

Return liquors/supernatant from thickening and dewatering processes and drainage from other
units will be collected in supernatant pumping station and pumped by submersible pumps to
Return Sludge Mixing Chamber.
 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 59 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

The pumps will be switched on and off by a level measurement which will be installed within
the sump pump. Water elevation will be controlled by to start/stop mechanism for prevention
overfilling and dry running. The sump pump will be covered with GRP and forced ventilated.
The extracted foul air will be treated by the odour control unit.
 Document Title:
PROCESS DESCRIPTION

Project Title:
EXPANSION OF AL KHOBAR SEWAGE TREATMENT PLANT PROJECT

Client: Contract No.: Document Number:

Rev 01 Page 60 of 60
National Water Company 701230311 701230311-KHR-PAS-010GEN-HYD-RE-00001

6.7 ODOUR TREATMENT

6.7.1 Odour Control Unit

Main Design Data

Number of OCU 2

Capacity of OCU, each 9,000 m³/hr

Type of OCU Bio-trickling filter

Explanatory Remarks

The odorous air will be collected from Inlet Chamber, Screening units, Trucked Sewage
Receiving Station, Grit & Grease Chambers, PST, Returns Liquor Pumping Station, Sludge
Mixing Tanks, SAS Balancing Tanks, Digested Sludge Storage Tanks and Sludge Thickening
& Dewatering Plant. The Bio-Trickling Filters are of a counter current design, where the gas
will enter the filter via the gas inlet at the bottom of the filter. The gas moves upward and passes
through the packing beds in vertical direction while the bed will be irrigated from above by
water through the spray nozzle situated immediately above the bed.

The odour treatment plant is a package plant, which will have its own local control panels.

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