Building Energy Efficient Technologies ZLD

Mr. Pradeep Rathy

VAPCO Engineers Pvt. Ltd.
VAPCO Organization
Why ZLD ?
Effluent treatment
Filtration
Evaporation
Drawing Schematic For Alchem
Presentation Outline
Environment
Systems
Process
Equipment
EPC
Division
Bio Nutrients
Ethanol Plants

Alcohol Plants

Starch Plants

Solvents Plants
Mechanical
Separation

Process
Equipment

Dairy
Systems
Bio Effluent
Treatment
Filtration
Evaporation
ZLD

Enzymes
Yeast-Pro

VAPCO AT A GLANCE
Why ZLD ?
5
Wastewater Treatment Basis
Disposal (under pollution Control Board Norms)
Water Scarcity (need for recycle)
Zero Discharge Norms (Government Regulation)
Common effluent treatment Plants
Process Products Recovery
Study of wastewater Generation Areas
Metal finishing/Automobile/steel mills /electroplating
Dying /Bleaching processes/tanneries/laundry-Textile
Industry
Acid-Alkali treatment- chemical industry/recovery of
chemical
Paper & pulp Industry, Leather Industry
Oily waste water- automobile/refineries
Pharmaceutical & food industry
Conventional STP
Thermal power/rubber industry/Fertilizers

Effluent parameters to be analyzed
Parameters

mg/lit

as CaCO3

Color





Turbidity





TSS





TDS





Odor





Temp





pH





Oil & grease





Heavy metals





Free & emulsified oil





Phenols





Cyanides





Hardness





Alkalinity





Kjeldahl Nitrogen





Heavy metals





COD





BOD





Phosphates





Silica





Chlorides





Sulphate





Sodium





Magnesium





Calcium





Chromium





chlorine





Heavy Metal Treatment
Effluent characteristics

Parameters

Unit

Variation limits

Ph

-

Acidic

Color

Hazen

Yellow red depending on
metallic compounds

Zn

Mg/l

Variable

Hexavalent chromium

Mg/l

Variable

Chromium total

Mg/l

Variable

Cyanide

Mg/l

Variable

Copper

Mg/l

Variable

Nickel

Mg/l

Variable

Chlorides

Mg/l

Variable

Fluorides

Mg/l

Variable

Phosphates

Mg/l

Variable

COD

Mg/l

< 250 /100

BOD

Mg/l

< 25

TSS

Mg/l

Variable

TDS

Mg/l

Variable

Cadmium

Mg/l

Variable

Toxic chemical

Mg/l

Variable

Iron

Mg/l

Variable

Ammonical nitrogen

Mg/l

Variable

Oil & grease

Mg/l

< 25

Conductivity

Micro Siemen

Variable

Turbidity

NTU

Variable

METAL TREATMENT BY HYDROXIDE PRECIPITATION


Metals + Hydroxides metal Hydroxides.

COMMON METHOD OF WASTEWATER TREATMENT FOR METAL REMOVAL -




Metal hydroxide
Polymer
Metal hydroxide
trapped in polymer
floc
Settled metal hydroxide
Inlet
Trapped solids
Filter media (sand)
Effluent
Sludge for dewatering
Plating wastewater - Chromium reduction
Wastewater containing hazardous
hexavalent chromium is treated
with chemical reduction process. Ph
is reduced to 3.0 or less and Sulfur
dioxide or SMBS or Sodium bisulfite
or ferrous sulfate is added to reduce
hexavalent chromium to trivalent
form.
A retention time of 45 minutes
should be maintained to ensure
adequate mixing and reaction with
SO2 or other chemicals. This water
then passed for next process of
metal removal.

Hexavalent
Chromium
Mixing tank or
reactor
PH adjustment
to 2-3 by
adding Acid
SMBS solution
Trivalent
Chromium.
Plating wastewater cyanide oxidation
Electroplating industry
using cyanide in process
can treat this before metal
treatment by alkaline
oxidation
Chlorine and caustic is
added for oxidation of
cyanide to cyanates.
In next tank again chlorine
is added to convert
cyanate to CO2 & nitrogen
with Detention time of 45
minutes

Cyanide
Sodium Hypo
chlorite
Caustic for pH
9.5 to 10.0
Mixing tank 1 Mixing tank 2
Sodium Hypo
chlorite
Caustic for pH
8.0
Cyanates
Effluent for metal
treatment
Metal treatment
Simply adjusting pH to 8.6 can effectively precipitate all the metals. Since all
metals display similar effect, it is clear that pH adjustment is critical in case
of metal removal.

Metal solubility are on the basis of theoretical wastewater, but in actual
number varies by presence of cyanide and ammonia in wastewater, which
can inhibit the removal of heavy metal from wastewater. So in general pH
should be adjusted to 9.0


Wastewater
collection tank
Mixin
g tank
PH adjustment to
9.0 by adding
caustic.
Polymer addition
Sedimentation
Dewatering of sludge
Backwash water containing heavy
metals
Wastewater
Sludge
Discharge
Adjust pH to discharge
Dosage calculation after Jar Test
Chemical dosages-
ml of chemical X conc. X 10 ppm dosage
liter of sample

Kg of chemical/day = ppm dosage x flow (m3/day)
Volume of solution Liters /day = kg of
chemical / % of solution
Per hrs. dosage(liters/hr) = solution Liters/ No. of hrs. dosage required
Pump capacity (LPH) = per hrs dosage + 10 % extra capacity .



Sludge Collection tank

Filter Press
Treated
water
SMBS Acid
Treated water
storage tank
M
G
F
A
C
F
NaOCl dosing
Polymer & lime
dosing in SMFT
Lamella clarifier
AUTOMOBILE INDUSTRY EFFLUENT TREATMENT
Textile Industry Effluent
Parameters

Unit

Variation limits

Ph

-

Highly alkaline

Color

Hazen

Variable

Zn

Mg/l

less

Chlorides

Mg/l

High

Sodium

Mg/l

High

Phosphates

Mg/l

High

COD

Mg/l

500-10000

BOD

Mg/l

High

TSS

Mg/l

Variable

TDS

Mg/l

Variable

Sulphide

Mg/l

Variables

Toxic chemical

Mg/l

Less
Iron

Mg/l

Less

Ammonical nitrogen

Mg/l

Nil

Oil & grease

Mg/l

Nil

Conductivity

Micro Siemen

Variable

Turbidity

NTU

Variable

Temperature

Degree

50- 150

Treatment of effluent
Temperature
reduction
Color reduction
Suspended solids
reduction
Organic matter
reduction
Sulphide , inorganic
less harmful
compound reduction
Raw Effluent
Aeration Tank
Sludge sump
AIR
BLOWER
FeSO4 LIME
POLYMERS
HRSCC
SECONDARY
CLARIFIER
Collection Tank
AIR
BLOWER
Dischar
ge
Suspended solids & Inorganic compound reduction
Dosing chemicals- Alum , Lime/ Caustic for pH 7-
8,Ferrous and ferric salts.
Polymer anionic dosages for floc formation and fast
settlement
Fluoride & phosphate removal-
Alum ( Ferrous )dosage with ph 7- 9.0- molar ratio
varies 2: 1 to 12.7 : 1
Lime + CaCl2 pH 8-8.5



Chemical Industry
Neutralization
Alkalinity reduction
Suspended solids
reduction
Silica reduction
Metal and organic
matter reduction
TDS reduction
Inorganic compound
reduction
Parameters

Unit

Variation limits

Ph

-

Variable

Color

Hazen

Variable depending on
compounds

Zn

Mg/l

Variable

Chlorides

Mg/l

High

Sodium

Mg/l

High

Phosphates

Mg/l

High

COD

Mg/l

Variables

BOD

Mg/l

Variable

TSS

Mg/l

variable

TDS

Mg/l

Variable

Sulphide

Mg/l

high

Toxic chemical

Mg/l

Variables

Iron

Mg/l

Variable

Ammonical nitrogen

Mg/l

Nil

Oil & grease

Mg/l

Nil

Conductivity

Micro Siemen

Variable

Turbidity

NTU

Variable

Alkalinity & Silica Reduction
Data required- alkaline hardness, EMA, anions,
alkalinity, silica.
Composition of compounds according to nature
and its availability
Requirement of lime , soda ash & dolomite
Dosage required and pump capacity


Paper and Pulp Industry
Temperature
reduction
Suspended solids
reduction
Color reduction
COD reduction
Parameters

Unit

Variation limits

Ph

-

Variable

Color

Hazen

Variable depending
on compounds

COD

Mg/l

Variables

BOD

Mg/l

Variable

TSS

Mg/l

Very high

TDS

Mg/l

Variable

Conductivity

Micro Siemen

Variable

Turbidity

NTU

Variable

temperature

degree

High

Treatment scheme
Sludge Collection tank

Filter Press
Treated
water
M
G
F
A
C
F
Final treated water tank
NaOCl Dosage
Equalization Tank
Lime dosing
T3
T2
Oily Wastewater treatment
Floating oil removal
Emulsified oil
removal
Suspended solid
removal
BOD removal

Reverse
Osmosis
Equalisation Tank
F e e d
P u m p
Cleaning & Process
tank
UF feed pump and UF
Filter Paper Oil Skimmer

Rotameter
RO PRODUCT TO STORAGE TANK. (May be used for
gardening, toilet flushing, car washing etc.)
RO REJECT TO SOLAR POND
Existing Waste
water Collection
tank
Oil
Skimmer


DAF
Primary
Clarifier
Equalization
Tank
Aeration
Tank
Secondary
Clarifier
Filter feed
Sump
Final
Treated
Water
Tank
RCC
Sludge
Sump
CONVENTIONAL OILY WASTEWATER TREATMENT
Food Industry & pharmaceutical
There should not be any
toxic or antibiotic
compounds in effluent ,
otherwise it has to be
disinfected before
treatment
Reduction BOD & COD
Reduction in SS
Reduction in oil & grease
Neutralization
Parameters

Unit

Variation limits

Ph

-

variabl

COD

Mg/l

Variables & high

BOD

Mg/l

Variable & high

TSS

Mg/l

Variable & high

TDS

Mg/l

Variable

Oil & grease

Mg/l

Variable

Phenols

Mg/l

Variable

Acid & alkali

Mg/l

Variable & high

Toxic chemical



variables

Treatment Scheme
Oil skimmer
Aeration Tank
SECONDARY CLARIFIER
AIR BLOWER
Sludge sump
AIR BLOWER
Primary settlment
Filter press
M
G
F
A
C
F
Treated
water
NaOCl Dosage
Discharge
Sewage treatment plant -Conventional
Treated
water
M
G
F
A
C
F
Settling
Tank
Final
Treated
water.

Sludge Collection
tank / SDB

Filter Press
Aeration tank
NaOCl
Dosage
Paramete
rs

Unit

Variation
limits
Ph

-

neutral

COD

Mg/l

< 650

BOD

Mg/l

< 350

TSS

Mg/l

<100

Oil &
grease

Mg/l

< 20

Toxic
chemical



Nil

Equalization
tank
Primary
treatment
Collection tank Aeration tank Secondary treatment MGF
ACF
Treated W Tank
Solid
separation
Solid
Incineration
Basket strainers
UF
Collection tank
CF RO
Solar ponds /
Evaporators
Solids
UV/UF
Sludge digestion
- discharge
- Recycle - Zero Discharge - process reuse
Filtration
30
Types of Filtration
Microfiltration
How it works?
Ultrafiltration
How it works?
Microfiltration vs. Ultrafiltration
Types of Filtration
2 Examples:
1. Cross Flow

2. Dead End Flow
Type 1: Cross Filtration
Flow parallel to
membrane surface

Does not cause buildup,
therefore does not suffer
from reduced flow
overtime

F = feed;
M = membrane;
P = permeate;
R = retentate (components
that do NOT pass through
the membrane)
Type 2: Dead End Flow
Flow perpendicular to
membrane surface

Causes build up of filter
cake on membrane

F = feed;
M = membrane;
P = permeate
(components that pass
through membrane)
Microfiltration
Separates soluble contaminants remaining
within the supernatant


Supernatant may include:
Other proteins
Bio-molecules
Un-used growth media

How does Microfiltration work?
Pressure driven process

Separates:
Components in a solution or
suspension based on
molecular size

Particles size range:
10m (starches) to aprx.
0.04m (DNA, Viruses,
and globular proteins)

Ultrafiltration
Usually used to
further separate any
contaminants able to
pass through the
microfiltration
membrane using a
pressure gradient
How does Ultrafiltration work?
Separates:
Particle size range:
0.1m to 0.001m

Usually based on
molecular weight
Typical range:
200 to 300,000 g/mole
Microfiltration vs. Ultrafiltration
Microfiltration:
Proteins act as the
permeate


Ultrafiltration
Proteins act as the
retentate
Pradeep Rathy
Microfiltration vs. Ultrafiltration
Microfiltration:
Separates larger particles
For example-
Colloids
Fat globules
Cells
Located upstream to reduce
load and fouling capacity on
ultrafiltration membrane
downstream
Ultrafiltration
Separates smaller particles
For example-
Macromolecules
However, processes
are basically
identical
Pradeep Rathy
EVAPORATION
Feed water Vaporised
tank feed water
Tank Volume out to
0.92 litre/cm atmosphere
Overflow
to drain Water
main
Steam in
Constant
level Sight
device glass
Steam
trap
Condensate
out
Condensate
tank
Tank Volume
1.31 litre/cm
Figure 1. The Evaporator
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PROCESS DESCRIPTION
OBJECTIVES
CONCENTRATE SOLUTE
RECOVER SOLVENT
FORM CRYSTALS
MECHANISM
HEAT EXCHANGE WITH PHASE
CHANGE
BATCH OR CONTINUOUS
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DESIGN FACTORS
SOLUTION FLUID VISCOSITY
HEAT TRANSFER COEFFICIENTS
PRESSURE DROPS
SOLUTE SOLUBILITY
SUPERSATURATED CONDITION
MATERIALS (BIO-MATERIALS) MAY
BE HEAT SENSITIVE
DEGRADATION TEMPERATURE
ELEVATED PRESSURE
BOILING POINT ELEVATION
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EVAPORATION DESIGN FACTORS
HIGH TEMPERATURE
REACTIONS
FOAMING
SCALING AND CORROSION
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OTHER DESIGN FACTORS
SPECIFIC HEAT
HEAT OF CONCENTRATION
FREEZING POINT VS. CONCENTRATION
GAS LIBERATION
TOXICITY
EXPLOSION HAZARDS
NEED FOR STERILITY
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EVAPORATION COMPARED WITH DISTILLATION
SOLUTE IN EVAPORATION IS GENERALLY NON-
VOLATILE, RELATIVE TO SOLVENT
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EVAPORATION EQUIPMENT
SUMMARIZED IN FIGURE 8.2-1
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EVAPORATOR EQUIPMENT
PLATE & FRAME - CRYSTALLIZERS
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OSLO TYPE CRYSTALLIZERS
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OTHER CRYSTALLIZERS
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THIN FILM EVAPORATORS
USED FOR
VISCOUS AND
THERMALLY
SENSITIVE MEDIA
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INTEGRATED PLANT

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EVAPORATOR CONFIGURATION
SINGLE STAGE EVAPORATORS
HEAT TRANSFER
) 1 2 . 8 ( ) (
1
= T T UA q
s
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MULTI-EFFECT EVAPORATORS
STEAM FROM ONE EFFECT IS THE HEAT SOURCE FOR THE
SECOND EFFECT
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MULTI-EFFECT COUNTERFLOW CONFIGURATION
FIGURE 8.2-3 FEED-
FOREWARD
PRESSURE IS
REDUCED IN EACH
STAGE
FEED & STEAM
ENTER THE SAME
STAGE IN THE
TRAIN
FIGURE 8.2-4
FEED-BACKWARD
PRESSURE IS
INCREASED IN
EACH STAGE
FEED & STEAM
ENTER FROM
OPPOSITE ENDS
OF THE TRAIN
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PARALLEL FEED
SOLAR EVAPORATION SYSTEM
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EVAPORATOR HEAT TRANSFER
OVERALL HEAT TRANSFER COEFFICIENTS
SEE TABLE 8.3-1
NEED TO KNOW RANGE TO REVIEW DESIGNS
PLATE & FRAME CAN HAVE HIGHER
COEFFICIENTS THAN SHELL & TUBE.

Pradeep Rathy
CHANGE OF PHASE HEAT TRANSFER
SECTION 4.8 FOR
SUMMARY OF
MECHANISMS
FIGURE 4.8-1
CONVECTION
NUCLEATE
TRANSITION
FILM
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HEAT TRANSFER COEFFICIENTS
BASED ON T


NUCLEATE BOILING
CONFIGURATION EQUATION RANGE REFERENCE
HORIZONTAL
3 / 1
2
) ( 1043 K T
K m
W
h A =
|
.
|

\
|

q/A, kW/m
2
< 16 (4.8-1)
HORIZONTAL
3
2
) ( 56 . 5 K T
K m
W
h A =
|
.
|

\
|

16 < q/A, kW/m
2
< 240
(4.8-2)
VERTICAL
7 / 1
2
) ( 537 K T
K m
W
h A =
|
.
|

\
|

q/A, kW/m
2
< 3 (4.8-3)
VERTICAL
3
2
) ( 95 . 7 K T
K m
W
h A =
|
.
|

\
|

3 < q/A, kW/m
2
<
63
(4.8-4)
FORCED
CONVECTION IN
TUBES
1551
3
2
) ( 55 . 2
sys
P
e K T
K m
W
h A =
|
.
|

\
|

P
sys
= kPa (4.8-5)
FILM BOILING
HORIZONTAL
TUBE
4 / 1
3
2
4 . 0 ( ) (
62 . 0
(
(

A
A + A
=
|
.
|

\
|
T D
T c h g k
K m
W
h
v tube
Pv vap v l v v

(4.8-6)

Pradeep Rathy
SINGLE STAGE MODELS
MASS AND ENERGY BALANCES
STEAM
CONDENSATE
FEED SOLUTION
PRODUCT VAPOR
PRODUCT LIQUID
F, T
F
,x
F
,h
F
V,T
BP
,y
V
,H
V
L, T
BP
,x
L
,h
L
S,T
S
,H
S
C,T
C
,h
C
C S V L F = + =
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MASS & ENERGY BALANCES
COMPONENT MASS BALANCE

SYSTEM HEAT BALANCE
VAPOR IN SOLUTE NO L x F x
L F
=
) 8 4 . 8 (
) 7 4 . 8 (
) 6 4 . 8 (
=
A = + = +
+ + = +

S q
H VH Lh S Fh
Sh VH Lh SH Fh
vap V L F
S V L S F
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OTHER DESIGN FACTORS
LOWER EVAPORATION PRESSURE
WILL INCREASE EFFECTIVE T
LOWER EVAPORATOR AREA
INCREASED SOLVENT CONDENSER AREA
HIGHER VELOCITIES MIST ELIMINATION
BOILING POINT ELEVATION
REDUCES EFFECTIVE T WITH INCREASING
CONCENTRATION
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BOILING POINT ELEVATION
DRINGS RULE
SOLUTION BOILING POINT
IS LINEARLY RELATED TO
PURE WATER NBPt AT P
SYS
FIGURE 8.4-2
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ENTHALPY-CONCENTRATION
HEAT OF MIXING
EFFECTS
NON-IDEAL
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104
Pradeep Rathy