معالجة الصرف الصناعى لشركة مواد غذائية وحلاوة وطحينة وزيوت نباتية

ARAB REPUBLIC OF EGYPT
EGYPTIAN ENVIRONMENTAL AFFAIRS AGENCY (EEAA)
EGYPTIAN POLLUTION ABATEMENT PROJECT (EPAP II)

Subject: INVITATION FOR QUOTATIONS FOR DESIGN, SUPPLY, INSTALLATION, ERECTION, COMISSIONING, START-UP AND TAKING OVER TEST, OF
INDUSTRIAL WASTE WATER TREATMENT PLANT,
AS A TURN KEY JOB

To:
Dear Sirs,
1. You are invited to: submit your most competitive quotation for Design, supply, installation, erection, commissioning, start-up and taking over test of Industrial Wastewater treatment plant to the following address:
Harvest Foods - El Bawadi Company
Plot no (4), Block no (11), 1st Industrial zone,
Borg El Arab City – Alexandria
Phone No: (+2) (012) 5883332
Fax No: (+2) (03) 4597908
E-mail: szaghloul@harvest.com.eg
All deliveries shall be installed at the facility to perform on the long run at efficiency that insure wastewater effluent complying with standerds of Egyptian Enviromental regulations for discharging to public sewer and according to specifications outlined in attached Technical Specifications document.
2. Price Quotation
a) The contract shall be for the full quantity according to technical specifications.
b) The prices will be fixed on C&F basis in L.E, or in equivalent convertible currency. Financial bid evaluation will be based on exchange rate to Egyptian pounds at the date of opening the financial offers.
c) Supplier responsible for installation, testing and commissioning.
d) Supplier has to quote for needed spare parts for 2 years.
3. Each supplier shall submit only one quotation. Quotation shall be submitted in writing.
4. Validity of Quotation
Quotation shall be valid for a period not less than 180 days after the deadline date specified for submission.
5. Evaluation of Quotations
The Purchaser will evaluate and compare the quotations according to the following terms:-
i. Overall completeness and compliance with the attached technical specifications.
ii. The characteristics of the factory’s final effluent shall be capable of reliably and consistently meeting the discharge limits mentioned in the Egyptian Law no. 93/1962 and its decree 44 for the year 2000 for Standards of effleunt discharged to public sewer (Environmental guarantee).
iii. Spare parts for two years.
iv. The operational guarantees of the equipment.
v. Time schedule of 9 months (270 days) to complete all facilities.
vi. Suppliers should undertake local training for the companies’ personnel during execution of the work by their specialists.

6. Award of Contract
The Purchaser will award the contract to the supplier whose quotation has been determined to be substantially responsive and who has offered the lowest evaluated quotation price.
Notwithstanding the above, the purchaser reserves the right to accept or reject any quotations and to cancel the quotation process and reject all quotations at any time prior to the award of contract.
The purchaser prior to expiration of the quotation validity period will notify the supplier whose quotation is accepted of the award of contract. The terms of the accepted offer shall be incorporated in the purchase order.
7. Terms of Payment
To be discussed and approved later with the nominated supplier.
8. Guarantee Period.
Minimum one (1) year guarantee from the date of operational acceptance.
9. You are requested to provide your offer latest by ??/ ??/ 2010.
10. We look forward to receiving your quotations and thank you for your interest in this project.
(Purchaser)

Harvest Foods - El Bawadi Company
Plot no (4), Block no(11),1st Industrial zone,
Borg El Arab City – Alexandria
Phone No: (+2) (012) 5883332
Fax No: (+2) (03) 4597908
E-mail: szaghloul@harvest.com.eg
________________________________________
INSTRUCTIONS TO BIDDERS________________________________________ Site
The works described in this tender shall be located at EL-Bawadi Company Located in Plot no (4), Block no (11), 1st Industrial zone, Borg El Arab City, Alexandria.
1. Eligible Bidders
Only bidders, who have extensive specialized experience in similar projects in supplying and installing of industrial wastewater treatment plants, are eligible to quote.
2. Source of Funds
This project is in connection with the program of “Egyptian Pollution Abatement Project (EPAP II)” which is funded by the World Bank and implemented by the Egyptian Environmental Affairs Agency (EEAA).

3. Visits to Site
It is the responsibility of the bidder to visit the plant site and make his own investigation and assessment of the work before tendering, including checking the analysis of the influent, making the required and necessary analysis and soil tests with no additional cost. The bidders must fill in - after his visit - the form given in the attached Annex1; Declaration of Visits to Site, and attach it to their offer. Offers that do not include the signed form shall not be considered.
4. Scope of Work
The project is a turn-key job including but not limited to the following:
• Designing, supplying and installing of complete Industrial Wastewater Treatment Plant to treat an average stream of 250 (m3/ d) and hourly peak of 15 (m3/ hr) with attached specifications.
• Commissioning, start up tests, and warranty for supplied equipment.
• Project components may include but not limited to the following:
 Design, supply and erection of bar and mechanical screens with a design capacity of 15 (m3/ hr).
 Design, supply and erection of an equalizing tank with a capacity of 100 m3 completed with two lifting pumps to homogenize the effluent coming from the production units.
 Design, supply and erection of a Dissolved Air Flotation (DAF) system with a design capacity of 15 (m3/hr) to remove suspended materials, oil and grease, and respectively greatly reduce the pollution load.
 Design, supply and erection of a complete sludge dewatering system.
 Supply and erection of necessary flow measuring and wastewater monitoring equipment.
 Design and construction of all civil works related to the project including tanks, bases … etc
• The final treated effluent should, in all times, meet the preferred limits shown in section 3 in the attached technical spacifications and based on the limits prescribed by decree 44/2000 as modified to Law 93, 1962.
5. Guarantee
All deliveries shall be in strict conformaity with the scope of work and spacifications and of first class. Warranty shall be for at least two years starting from the date of preliminary take over. In case any major key parts have to be replaced, these parts shall have a new guarantee period of one year from the date of their installation after being replaced at site.
6.1. Performance guarantee
• The self monitoring system will include the identification of monitoring indicators (T.S.S, BOD, COD and Oil & Grease) and scheme to enable the facility to monitor and maintain the efficiency of the process during operation.
• The contractor shall guarantee the normal smooth running of the Industrial Wastewater treatment plant (IWWTP) after implementing the project for two years continuous running according to contractor operating instructions and conditions from the date of the end of the successful performance running test (Take Over Test)
• The equipment will be brand new
• The contractor will replace any part, which shows any defect, free of charge and on his own expenses, also will guarantee it for one year from the date of replacement.
6.2. Operational gurantee
• The evaluation criteria for the IWWTP shall be the plant input/ output flow and discharged sludge volume as well as electric power and chemicals consumptions compared to that provided in the contractor design.
• The contractor shall insure that the IWWTP should operate efficiently with the given rate in his design for power and chemicals consumptions.
6.3. Environmental gurantee
• The contractor shall guarantee the following indicators levels as maximum levels in outflow of the IWWTP:
Indicator Unit Environmental Guarantee
pH --- 6-9.5
TSS mg/ l 700
BOD mg/ l 1000
COD mg/ l 550
O & G mg/ l 90

6. Documentationtion required from the Bidder
7.1. Submittals required with quotations
a) Vendor data fully describing the bidder’s organization, field of specialization, and past experience in similar Project and after sale service capabilities.
b) Declaration of site visit, the bidder shall submit a declaration written on the bidder’s letterhead (Annex 1).
c) A description of the treatment process.
d) A description of anticipated operations and maintenance requirements including: total staff requirements; organizational chart; Staff qualifications; preliminary list of recommended O & M vehicles, equipment, tools, supplies and spare parts.
e) A list of key process equipment showing the equipment size, capacity (e.g. hydraulic, pollutants loads) specifications. Motor information, material of construction, country of origin and original catalogues in english
f) Process flow diagram showing all main and side flow streams and all process control valves.
g) Preliminary general layout diagram, showing the arrangement of the plant components over the proposed area.
h) A schedule for mobilization, delivery of equipment; design and construction of site facilities, process tanks, buildings and pipelines, and commissioning of the plant.
i) Summary of supplier offer.
j) Total power consumed by Plant Equipment for normal operation in Kwh per day.
k) Total chemicals and others consumables consumed by the Plant for normal operation.
l) Environmental, Safety and Health data sheet for all chemicals intended to be used in the treatment plant.
m) Warranties and performance guarantees.

7.2. Submittals required prior equipment delivery for checking and approval by purchaser
a) A set of civil and structural construction drawings.
b) A detailed specification of equipment, motors, pumps including name of manufacturer and catalogues in English.
c) Separate general arrangement drawings for each unit process in the plant including plans, sections, elevations and details drawn to scale.
d) Hydraulic profile.
e) Foundation and installation drawings including data covering weight of equipment and tanks.
f) Detailed process and hydrolic calculations.
g) P & ID drawings; written instrumentation and controls system philosophy; list of the primary elements; and system facilities that will be provided.
h) Electric circuit diagram.
i) Written description of standard codes followed during the design.
7.3. Submittals required prior to start up and comissioning
a) Two operations and maintenance manuals including for each product or piece of equipment; equipment function, operating characteristics, regulation and control, and shut down. Manuals must be specific to the products supplied herein and the application and operating conditions of this Project.
b) Complete detailed written preventative maintenance instructions in Arabic and in English Language.
c) A complete inventory of all parts and components.
d) A complete set of as built drawings for all installed systems and equipment
e) Recommended spare parts lists for 2 years and sources of supply for the parts.
f) Written explanations of all safety considerations relating to operation and maintenance procedures.
g) Name, address and phone number of contractor authorized service representative or installer.
h) Trouble shooting instructions.
i) Performance test procedures and parameters.
j) Take-over procedure.

7. Obligatory Condition
1. Only bidders who have extensive specialized experience in similar project in IWWTP are eligible to bid.
2. Bidders must visit the site and fill in the attached Annex 1 “Declaration of Visit to Site”
3. All equipment, auxiliaries, instrumentation, alarms and control system shall be made or approved by USA, European (EC) or Japanese manufacturers.
4. Material of construction should be such that it guarantees steady performance for a minimun of 15 years for metallic parts (galvanized piping, pumps, steel works … etc) and 20 years for concrete works.
5. It is the responsibility of the bidders to build his design upon WW samples collected and analyzed by himself and at no extra cost.
8. Technical Evaluation of Offers
The offers of eligible Bidder shall be technically evaluated based on the following elements:
- Legal structure of the supplier in Egypt.
- Technical offer information and dgree of completeness.
- Origin of supplied equipment.
- Delivery period of scope of work.
- Past experience of Bidder in similar projects in Egypt and abroad.
- After sales capabilities of the Bidder.
- Chemical and power consumptions.
- Area requirement.
- Sludge volume and consistency after dewatering.

TECHNICAL SPECIFICATIONS________________________________________
Description of Works
1. Site Description
EL-Bawadi Company is an Egyptian company established and started production in 1990 under the ownership of Halwani Ekhwan Company. In 2005 the company became a subsidiary of Harvest Foods – Egypt.
The Company’s factory is located at New Borg El Arab city west of Alexandria Governorate in the 1st industrial zone Plot no (4),Block no (11).
The Factory occupies an area of about 4000 m2 .All the production and service units are distributed neatly on the available area and employs 250 persons. The factory operates 3 (shifts/day), 8 (hours/shift), 330 (day/year).
A layout diagram for the factory indicating the location of the proposed area (6m width x 16m Length x 3.4m hight) for installion of the treatment plant is shown in figure 1 and 2
2. Basic Information
The Factory specialized in sweets production. It owns two production lines for Halwa and Tehina products. The main raw materials used in production are Sesame, Sugar and Saponaria root.
The Factory consumes about 255 m3 of city water per day. The main source of water pollution in the factory comes from the waste effluent produced from washing and sesame peeler units. The factory’s industrial wastewater stream is characterized with high COD, BOD and TSS values.This stream has an avarage flow rate of about 250 (m3/day) and discharged directly into the public sewer without any kind of treatment.
The contact person assigned in the factory for clarifying any technical queries is:
Eng. Saad Zaghloul Quality Assurance Manager
Tel: 03/457761 Fax: 03/457762

3. Design Data
Currently, all Industrial wastewater streams from the factory is discharged directly to public sewer with a total average flow of 250 (m3/d) and maximum flow of 300 (m3/d). The levels of pollution parameters which characterize the main waste streams produced from production units are shown in Table (1). These values represent the current situation in the factory after removing the Molasses production unit. Several analysis samples were taken by the company (Annex (2)) and can be used as a guideline.
Table (1): Recent levels of pollution parameters in waste streams compared with law limits and preferred effluent quality limits from the proposed IWWTP
Parameter Current concentation Law limits
(44/2000) Preferred Limit
(≈10% less than law limits)
pH 7.16 6-9.5 6-9.5
TSS, mg/l 955 800 700
COD, mg/l 2080 1100 1000
BOD5,mg/l 1380 600 550
O&G, mg/l --- 100 90

Results shown in Table (1) can also be used as guidelines, but it is the full responsibility of the contractor to depend on his own analysis for the wastewater streams. A treatability study could be necessary prior design to fulfill the required performance of the proposed system and should be conducted by the bidder and under his responsibility.
The treated effluent design parameters shall under all conditions comply with the limits of Law No. 93/ 1962 and its supplemented Decree No. 44/ 2000, for discharging to the public sewer system. Bidders shall be fully conversant with these limits.
The process design shall take into account normal operating fluctuations to perform significantly within these normal limits in accordance with accepted practice.

4. Process Description
The following description is considered as a guideline only for the bidder and not an actual one.
The combined wastewater streams is passed through bar screen then fine mechanical screen to remove large particles (sessame peels, Halwa pieces … etc).
The wastewater is then collected in an equalizing tank for homogenization then pumped to the Dissolved Air Flotation (DAF) system where appreciable amounts of fine suspended solids and oil and grease are removed leading to a great reduction of TSS, COD, BOD and oil and grease levels.
Treated effluent from DAF unit is discharged to public sewer as being within the allowable limits.
Sludge from DAF unit is then passed to the sludge holding tank to achieve additional sludge stabilization and decrease its volume, then pumped to the dewatering system.
5. Scope of Supply
The scope of supply of the Wastewater Treatment plant components shall be according but not limited to the following:
5.1. Chemical Treatment (300 m3/day)
5.1.1. Bar Screen
Quantity: One
Type: On line bar screen
Solid width: 10 mm
Material: Stainless steel 304.

5.1.2. Fine Mechanical Screen
Quantity: One
Type: Aqua rake on line screen
Solid width: 1 mm
Capacity: 15 m3/ hr
Material: Stainless steel.
5.1.3. Equalizing Tank
Quantity: one
Capacity: 100 m3
Material of Construction: Concrete, lined from inside with impermeable agent. Preferably underground due to the limiting available area.
The tank should be equipped with a stainless steel submersible mixer and air diffusers coarse bubble type to avoid any anaerobic growth or sludge settling.
5.1.4. Influent lifting pumps
Quantity: two (one standby) to transfer the wastewater from the equalizing tank to DAF unit
Flow rate: 15 m3/ hr
Type: Submersible
Pumps will operate automatically in sequence according to the quantity of the effluent received in the equalizing tank.
Material of construction: Casing: cast iron and impeller: stainless steel
Shaft seal: stuffing box
Head: according to bidder’s design
Motor: Squirrel cage electric motor with IP68 protection
Power supply: 380/50HZ
Isolating valve: gate valve per pump header
Non return valve: swing check valve per pump header
Control: float switches or equivalent

5.1.5. Dissolved Air Floatation Unit (DAF)
Capacity: 15m3/ hr
Material of construction: stainless steel and HDPE
Quantity: one
Accessories:
• Flotation Unit made of stainless steel 304. The tank/ functional elements are equipped with pipes made of stainless steel. The flange connections are also made of stainless steel
• Pipe flocculator unit for mixing chemicals made of HDPE.
• 2 injection points for flocculant and coagulant
• Stainless steel mixer
• AISI 304 skimmer for floating sludge with adjustable speed control driven
• Recirculation pump, horizontal, Centrifugal capacity according to bidder’s design
• Polypropylene corrugated plates
• Aeration system, the bidder’s must give his own calculation for the system, air requirements, and aeration devices.
5.1.6. Chemical dosing units
1. Chemical dosing pumps
Quantity: two for coagulant and flocculant.
Min Flow: as per your design
Type: Diaphragm or equivalent
Power supply: 220/1Ph/ 50HZ
Valve application: Injection valve type
Material of construction: Suitable for the type of chemical to be handled
2. Chemicals tanks
Quantity: two
Capacity: 500 liters
Material of construction: rotation molded polyethylene
Tank is complete with transfer pipe work and associated fittings
3. Polyelectrolyte preparation and dilution unit include
Agitator, Level control, Powder feeder, Polyethylene tank with suitable capacity.
5.2. Sludge-dewatering system
5.2.1. Sludge holding tank
With adequate capacity not less than two days for sludge accumulation as it receives sludge from DAF unit, capacity to be determined according to bidder’s design. Tank is fitted with sludge inlet connection and sludge draw-off connection to sludge dewatering unit
Tank to be constructed from epoxy lined steel or water retaining reinforced concrete structure
5.2.2. Two sludge transfer pumps (one stand by)
Positive displacement. Air operated double acting diaphragm type, complete with motor control and pressure relief devices, Power: 380/3Ph/50HZ
Control: float switches or equivalent
5.2.3. Flocculent dosing unit
200 L polypropylene tank.
Flocculants dosing pump, flow rate as per contractor design.
5.2.4. One Filter press
Side type with minimum of 20 recessed square chambers. Center feed and free drainage to drip trays for gravity return to the treatment plant. Polypropylene cloth, manual plate movement and press closure by manual /hydraulic pump operation
The dewatered sludge should contain a minimum of 25-30% solids
Bidder can offer alternative to filter press such as belt press, decanter centrifuge …etc

5.3. All Necessary Control Instruments required for pressure, level flow …etc should be included.
5.4. Control Panel
Outdoor type, complete with necessary starter, overload protection, duty selector switch, run/stop indicator lamp and all other necessary accessories.
5.5. Pipe network.
All necessary structures, pipe-work, valves and fittings, electromechanical equipment, instrumentation for operation and control miscellaneous equipment necessary to:
• Transfer waste effluent from existing collection pit to the equalizing tank.
• Transfer effluent from the equalizing tank to the DAF unit.
• Transfer treated effluent to the sewer line.
• Transfer sludge from DAF unit to the sludge holding tank then to the dewatering device.
5.6. Monitoring Devices
Bidders should include the necessary test kits for analysis and control process.
• Flow measuring pH meter.COD (HACH system or equivalent).BOD apparatus, with thermostatically controlled incubator.
• Electric balance.
• T.S.S meter.
• Extra spare electrode for pH and conductivity meters.
• Glassware (Imhoff cones, graduated cylinders, glass beakers, flasks, beakers … etc).
• Lab chemicals.
• Sludge stability.
• Thermostatically controlled laboratory dryer.

المواصفات الفنية
يقع المصنع على مساحة 4000 متر مربع ويعمل به 250 موظف ويعملوا 3 ورديات بمعدل 8 ساعات/الوردية بمعدل 330 يوم/السنة
وتقع محطة المعالجة فى موقع مساحته ( 6 متر عرض/16 متر طول/ 3.4 متر ارتفاع)
المصنع مخصص لانتاج الحلاوة الطحينية والطحينة حيث المواد الخام المستخدمة السمسم والسكر والبنجر
كمية مياه الصرف اليومية=255 متر مكعب/يوم تاتى مباشرة من خطوط الانتاج من غسيل السمسم وخلطه مما يؤدى الى ارتفاع معدلات الاكسجين الحيوى المذاب والاكسجين الكيماوى المذاب والمواد الرغوية العالقة متواجدين فى كمية مياه صرف يومى=250-255 متر مكعب/يوم منصرفين مباشرة فى شبكة الصرف العمومى
بما ان كمية مياه الصرف كاملة تصرف مباشرة الى شبكة الصرف العمومى بمعدل يتراوح مابين 250-300متر مكعب محققة معدلات ملوثات كبيرة جدا فالاس الهيدروجينى=7.16 ونسبة المواد الرغوية العالقة=955 محم/لتر ونسبة الاكسجين الكيماوى المذاب=2080 مجم/لتر ونسبة الاكسجين الحيوى المذاب=1380 مجم/لتر فيترتب عليه انشاء محطة معالجة صرف للحصول على اس هيدروجينى=6-9.5 ونسبة المواد الرغوية العالقة=800مجم/لتر ونسبة الاكسجين الكيماوى المذاب=1100مجم/لتر ونسبة الاكسجين الحيوى المذاب=600مجم/لتر بناءا عن القانون 93/1962 والمعدل بالقانون 44/2000
تجمع مياه الصرف فى خزانات تجميع مياه ويتم تقليبه ببار كبير ثم ببار ميكانيكى رفيع لتحريك وفصل الجزيئات الكبيرة والمتوسطة وترسيبها الى اسفل الخزانات
وتجمع مياه الصرف بعد التقليب فى خزانات معادلة ليتم تجانسها ثم ترفع بالطلمبات خلال منطقة المعالجة البيولوجية بالهواء لازالة المواد الصلبة والزيوت والشحوم وتقليل نسبة الاكسجين الحيوى المذاب والاكسجين الكيماوى المذاب ونسبة المواد العالقة الرغوية
حيث تتحرك مياه الصرف المعالج من وحدة المعالجة البيولوجية والكيميائية الى شبكة الصرف العمومى بينما المخلفات الناتجة من عمليتى المعالجة الكيميائية والبيولوجية تصرف الى خزان معالجة المخلفات اتثبيتها ومعالجتها قبل وضعها بوحدة المرشح المضغوط(الفلتر بريس)

طريقة التصنيع
اولا/المعالجة الكيميائية
كمية الصرف العمومى=300 مترمكعب/يوم
ثانيا/قلابات استانلس استيل كبير من الاستانلس 304 لتحريك مخلفات سمك 10 مم
ثالثا/قلابات استانلس استيل ميكانيكى رفيع سرعة 15 متر مكعب/ ساعة من الاستانلس 304 لتحريك مخلفات سمك 1 مم
رابعا/خزان معادلة خرسانى سعة 100 متر مكعب مزود بقلاب من الاستانلس استيل ومقلبات هواء(ديفيوزر)لتقليب المياه مع الهواء لمنع نمو البكتريا او تجلط المخلفات
خامسا/عدد 2 طلمبة رفع قدرة 15 متر مكعب/ساعة بقلب استانلس استيل وجسم من الحديد المطاوع مزودة بصمام لمنع دخول الهواء والعوالق الى داخلها بقدرة كهربائية=380/50 هيرتز لنقل المياه من خزان المعادلة الى وحدة المعالجة البيولوجية بالهواء
سادسا/وحدة المعالجة البيولوجية(داف) سعة 15 متر مكعب/ساعة مصنعة كجسم ومواسير وفلانشات من الاستانلس استيل 304 والمواسير الخاصة بمزج الكيماويات وحقنها من البولى ايثيلين العالى الجودة ومزودة بمنطقتين لحقن المجلطات والندافات ومزودة بقلاب ميكانيكى من الاستانلس استيل وطلمبات تقليب ورفع المياه المعالجة من الوحدة الى خارجها وطلمبة تخلص من المخلفات وفى النهاية عدد من الواح البولى بروبيلين تمثل الواح اللاميلا لعملية المعالجة الطبيعية
وحدة حقن الكيماويات
اولا/طلمبات حقن الكيماويات
طلمبة لحقن المجلطات وطلمبة حقن للفلوكات قدرة 220/50هيرتز بصمام ترشيح لمنع دخول الهواء ومخصصة لحقن الاحكاض والكيماويات
ثانيا/خزانات الكيماويات
عدد 2 خزان سعة كل واحد نصف متر مكعب مصنعين من البولى ايثيلين موصلين بمواسير وفلانشات وصمامات بولى ايثيلين وحدة مزج كيماويات داخلية
وحدة رفع المخلفات
اولا/ خزان تجميع المخلفات
سعة يومين مخلفات اى ثلث كمية المياه المعالجة لمدة يومين موصلين من خزانات المعالجة البيولوجية والكيميائية ومتصل بوحدة الفلتر بريس لضغط المخلفات على هيئة قوالب ورفعها من الموقع
ثانيا/طلمبات رفع المخلفات
عدد 2 طلمبة واحدة اساسية والاخرى احتياطى تشغيل بقوة 380/50 هيرتز
وحدة حقن الفلوكات
مكونة من خزان بولى بروبيلين سعة ربع متر مكعب
وحدة فلتر بريس
مكون من 20 حجرة اغشيتها من البولى بروبيلين يدوى التشغيل للقواطع والضغط يتم يدويا وهيدروليكيا بطلمبات للتعامل مع مخلفات بنسبة صلابة 25-30%

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