Thesis paper about PLC Based water Treatment Plant Zero liquid discharge 2024

PLC Based water Treatment Plant With Zero Liquid
Discharge
Submitted by
Md. Mehedi Hasan
ID No:44210102305
Supervised by
Anika Fariha Rashid
Lecturer
Department of Electrical & Electronics Engineering, NUB
In partial fulfillment of the
requirements for the Degree of
Bachelor of Engineering
February 2024
Department of Electrical & Electronic Engineering

Northern University Bangladesh
Classification: Internal
Declaration of Candidates
We hereby, declare that the work presented in this Thesis is the outcome of the thesis work,
investigation performed by us under the supervision of Anika Fariha Rashid , Lecturer, Dept. of
EEE Northern University Bangladesh. We also declare that no part of this report has been or is
submitted elsewhere for the award of any degree or diploma.
……………………………………………..
(Signature and Date)
Md. Ranu Sarker

ID no. 44210102322
……………………………………………..
Md.Mehedi Hasan
ID no. 44210102305
……………………………………………..
Md.Mizanur Rahman
ID no. 44210102280
……………………………………………..
Orun Badsha Rubel

ID no.44210102308
……………………………………………..
Md. Kamrul Islam

ID no. 44210102311
……………………………………………..
Board of Examiners
1. Ms. Anika Fariha Rashid

(Supervisor)
Lecturer, Dept. of EEE
Northern University Bangladesh (NUB)
Ms. Tahia Tasnim Islam
(Examiner)
2. Mr. Sharif Uddin

(Examiner)
3. Mr. K.M Daiyan

(Examiner)
…………………………..
Dr. Mizanur Rahman
Associate Professor & Head
Department, EEE
ABSTRACT
Zero liquid discharge (ZLD) refers to a treatment process in which the plant discharges no
liquid effluent into surface waters, in effect completely eliminating the environmental
pollution associated with treatment. Apart from this benefit, a ZLD process also makes
effective use of wastewater treatment, recycling, and reuse, thereby contributing to water
conservation through reduced intake of fresh water. This paper includes effluent treatment
methods, the prospect of ZLD in Bangladesh, the benefits & challenges and equipment
overviews. Zero discharge solutions can be accomplished by concentrating the effluent using
various techniques, including membrane-based and multiple effect evaporation-based
systems, and recovery and recycling of water.
Acknowledgements
I extend my deepest gratitude to those who have played an instrumental role in the completion of
this thesis on Zero Liquid Discharge (ZLD). This journey has been both challenging and rewarding,
and I owe much of its success to the support and encouragement of the following individuals and
organizations.
First and foremost, I express my sincere appreciation to my thesis advisor, Anika Fariha Rashid, for
their invaluable guidance, unwavering support, and insightful feedback throughout the entire
research process. Their expertise in the field of PVM factory has been a beacon, illuminating the
path toward a comprehensive understanding of ZLD technologies.
I am thankful for the encouragement and mentorship provided by the members of my thesis
committee, Mizanur Rahman, Orun Badsha Rubel, Md. Kamrul Islam and Md. Ranu Sarker. Their
constructive critiques and thoughtful suggestions have significantly enriched the quality of this
work.
Special thanks are due to Mohammad Rasel Mahmud Executive – Safety, Health and Environment,
whose willingness to share their practical insights and experiences in the field of ZLD proved
instrumental in shaping the real-world applications section of this thesis. Their generosity in sharing
knowledge has been an invaluable asset.
I extend my appreciation to the staff and resources of Northern University Bangladesh (NUB),
whose facilities and library services provided an essential foundation for the research conducted.
The academic environment and access to scholarly materials greatly contributed to the depth and
rigor of this thesis.
To my friends and family, who provided unwavering support and understanding throughout this
academic journey, I extend my deepest gratitude. Your encouragement and belief in my abilities
sustained me during challenging times.
Finally, I dedicate this thesis to Bangladesh's environmental authority, whose inspiration has fueled
my passion for contributing to sustainable water management solutions. Your impact on my
academic and personal growth is immeasurable.
This thesis is a culmination of collective efforts and support, and I am truly grateful for the
collaborative spirit that has fueled its completion.
TABLE OF CONTENTS
ABSTRACT................................................................................................................ i
ACKNOWLEDGEMENT…………………………………………………………...ii
TABLE OF CONTENTS .....................................................................................….iii
LIST OF FIGURES AND TABLES.......................................................................... v
1 INTRODUCTION ............................................................................................................... 1
1.1 Zero Liquid Discharge ................................................................................................. 2
2 Effluent Treatment Methods ................................................................................................ 4
2.1 Physical Unit Operations [4] ....................................................................................... 4
2.1.1 Screening ....................................................................................................... 4
2.1.2 Flow Equalization ......................................................................................... 5
2.1.3 Sedimentation and Filtration ......................................................................... 6
2.1.4 Aeration ......................................................................................................... 6
2.2 Chemical Unit Processes [4] ........................................................................................ 7
2.2.1 pH Control ..................................................................................................... 7
2.2.2 Chemical Coagulation and Flocculation ....................................................... 8
2.3 Biological Unit Processes [4] ....................................................................................... 8
2.3.1 Activated Sludge ........................................................................................... 9
2.3.2 Fixed Film ..................................................................................................... 9
2.4 Physio-chemical Treatment........................................................................................ 10
2.5 Physio-chemical and Biological Treatment ............................................................... 10
3 Programmable Logic Controller………………………………………………………..11
3.1 Introduction…………………………………………………………………………11
3.2 Definition……………………………………………………………………………11
3.3 Historical Background of PLC………………………………………………………12
3.4 Basic PLC Architecture …………………………………………………………….12
3.4.1 Microprocessor……………………………………………………………….13
3.4.2 Memory……………………………………………………………………….14
3.4.3 Programing Device……………………………………………………………14
3.4.4 Input & Output Section……………………………………………………......14
3.5 The Guts inside of PLC……………………………………………………………..14
3.6 Working Function of Each Part of PLC……………………………………….…...15
3.7 PLC Operation……………………………………………………………………..15
3.8 Features and Advantaged Of PLC………………………………………………….16
3.9 Disadvantaged Of PLC……………………………………………………………..17
3.10 Difference Between ………………………………………………………………..17
3.11 Requirement Component Of ZLD for PLC……………………………………….18

3.11.1 Relay
3.11.2 Operation of Relay
3.11.3 Type of Relay
3.11.4 Application of Relay
3.11.5 Solenoid Valve
3.11.6 Operation of Solenoid Valve
3.12 Arduino Add Base Scanda For water plant………………………………………….21
3.12.2 Hardware Component ……………………………………………………….21
3.12.3 Summary …………………………………………………………………….22
3.12.4 Problem Statement …………………………………………………………..25
3.12.5 Theoretical Framework………………………………………………………..26
3.12.6 Practical Farmwork…………………………………………………………...34
4 Introduction of ZLD in Bangladesh ............................................................................... 46
4.1 Reasons to Introduction of ZLD in Bangladesh ...................................................... 46
4.1.1 Ground Water Level ............................................................................................... 47
4.1.2 National Standards for Wastewater ........................................................................ 49

4.1 Benefits and Challenges Facing the ZLD ................................................................ 48
4.12.4 Benefits of ZLD .......................................................................................... 49
4.12.5 Challenges of ZLD...................................................................................... 49
5 Overview on Zero Liquid discharge .............................................................................. 50
5.1 Process Selection ..................................................................................................... 51
5.2 Some ZLD Process Examples: .................................................................................. 54
5.2.1 Ionics’ EnChem. A ZLD-solution for the semiconductor industry ............................ 55
5.2.2 Tenergys’ plating waste water recovery system ......................................................... 55
6 Achieving ZLD: Equipment Overview .......................................................................... 56
6.1 Reverse Osmosis (RO) ............................................................................................. 57
9.2 Electro-dialysis reversal (EDR) .............................................................................. 58
9.3 Evaporator ............................................................................................................... 58
9.4 Crystallizer ............................................................................................................... 59
9.5 Spray Dryer .............................................................................................................. 59
7 Analysis
7.1 Introduction ………………………………………………………………………..60
7.2 Performance of ZLD-ETPs ………………………………………………………..71
7.3 Performance of ETPs………………………………………………………………..76
7.4 Assessment of Pollution Load ………………………………………………………80
7.5 Analysis of Baseline Data of Selected Industries
7.6 Assessment of ZD Status of ZLD-ETP Industries
7.7 Sludge Management
7.8 Cost Analysis
7.9 Technological Assessment
8 Discussion
7.1 Introduction
7.2 Discussion on Proposed Technological Schemes in 3R Plan
7.3 Discussion on Progress of ZLD
7.4 Discussion on Performance of ZLD and ETPs
7.5 Discussion on Technologies
7.6 Assessment of ZLD and ETPs In Terms of Cost
7.7 Discussion on Handling Mechanism of Reject/Concentrate of ZLD
System
7.8 Discussion on Operation and Maintenance of ETP
7.9 Evaluation of Reduction in Groundwater Extraction
9 Conclusions
9.6 Conclusions
9.7 Recommendations
9.8 Constraints and Limitations
9.9 Advantage of ZLD
10 Future work
11 Reference
CHAPTER 1
1 INTRODUCTION
In the past several decades, industrial production has increased in Bangladesh. Water
consumption for industrial use has consequently risen and will continue to rise. Ecological
issues are an integral and important part of the environmental issues challenging Bangladesh.
Poor air quality, water pollution, and garbage all affect the quality of food and the
environment necessary for ecosystems to thrive. Nowadays, Environmental concerns are
steadily increasing, and regulatory authorities are constantly tightening the environmental
standards, insisting that industries adopt advanced wastewater treatment technologies,
including ZLD solutions.
Today few industries are concerned with developing ZLD solutions that address some of the
following challenges:
1. Innovative and customized solution offerings
2. Highly corrosive effluent and the selection of metallurgy
3. Recovery of pure process condensate for reuse and recycling
4. Operating temperature and pressures and scaling and fouling tendency
5. Continuous operation of the system with minimization of cleaning-in-place (CIP) effluents
6. Selection of appropriate type of evaporator effects in multi effect evaporation system
7. Optimization of CAPEX and OPEX for ZLD solutions.
1
1.1 Zero Liquid Discharge
Any process or combination of processes, by virtue of which there is no liquid effluent, or

discharge from a process plant
It implies that wastewater is treated and effectively recycled and reused such that there is no
effluent discharge. ZLD is usually accomplished by concentrating the effluent using various
techniques, including membrane-based and multi effect evaporation based systems. ZLD
involves:
• The elimination of the liquid waste effluent stream from the plant
• The recycling of recovered water and solids
• The establishment of no liquid pollutant norms.
If implemented correctly, ZLD has the potential not just to alleviate concerns of effluent
discharge but also to lead to water conservation, which is critical for regions experiencing
water scarcity.
If implemented correctly, ZLD has the potential not just to alleviate concerns of effluent
discharge but also to lead to water conservation, which is critical for regions experiencing
water scarcity.
2
Typically, ZLD systems are used where there are environmental limitations such as water
insufficiency and where strong environmental regulations are obligatory; either because water
resources are scarce or an industry’s activity is highly polluting. In principle, the end goal of
ZLD is to eliminate (to the extent feasible) the discharge or disposal of liquid waste from a
facility, wherein no wastewater gets discharged to surface water bodies. This is ultimately
accomplished by recycling, reusing or reducing the volume of waste stream, primarily
including water-based streams. The non-water components of a wastewater come from either
the manufacturing process itself or from a cleaning process and can include any number of
materials, chemicals, oils or solids. Typical waste streams that produce large volumes of
wastewater include cooling tower blowdown, gas scrubber blowdown, ion-exchange
regeneration effluent and rinses, plant wash down and rain water runoff, and process wastes.
These come from a wide variety of industries, including but certainly not limited to:
• Metal Working
• Metal Finishing
• Manufacturing/Production
• Transportation
• Water Treatment
• Material Recycling
• Pharmaceutical
• Food and Beverage
3
CHAPTER 2
2 EFFLUENT TREATMENT METHODS
Effluent can be treated in a number of different ways depending on the level of treatment
required. These levels are known as preliminary, primary, secondary and tertiary (or
advanced) [1]. Conventional wastewater treatment consists of a combination of physical,
chemical, and biological processes (Table 2-1) and operations to remove solids, organic
matter and, sometimes, nutrients from wastewater [2]. Many of these processes will be used
together in a single treatment plant.
Table 2-1: Wastewater Treatment Levels and Processes [3]

Treatment Level Description Process
Preliminary Removal of large solids such as rags, sticks, Physical
grit and grease that may damage equipment
or result in operational problems
Primary Removal of floating and settle able materials Physical and
such as suspended solids and organic matter chemical
Secondary Removal of biodegradable organic matter Biological and
and suspended solids chemical
Tertiary/Advanced Removal of residual suspended solids / Physical, chemical
dissolved solids and biological
2.1 Physical Unit Operations [4]

Common physical unit operations include among other processes screening, flow
equalization, sedimentation, clarification and aeration.
2.1.1 Screening
A screen with openings of uniform size is used to remove large solids such as plastics, cloth,
polythene etc. which may damage process equipment, reduce the effectiveness of the ETP or
contaminate waterways.
4
2.1.2 Flow Equalization
There are several different steps in the industrial processes and therefore wastewater quality
and quantity varies over time. ETPs are usually designed to treat wastewater that has a more
or less constant flow and a quality that only fluctuates within a narrow range. The
equalization tank overcomes this by collecting and storing the waste, allowing it to mix and
become a regular quality before it is pumped to the treatment units at a constant rate. To
determine the required volume of an equalization tank the hourly variation of flow needs to
be determined.
5
2.1.3 Sedimentation and Filtration
The flocs formed in flocculation are large enough to be removed by gravitational settling,
also known as sedimentation. This is achieved in a tank referred to as the sedimentation tank,
settling tank or clarifier. Sedimentation is also used to remove grit and suspended solids, to
produce clarified effluent, and to thicken the sludge produced in biological treatment.
Flocculation and sedimentation should remove most of the suspended solids and a portion of
the BOD [5].
2.1.4 Aeration
Aeration is required in biological treatment processes to provide oxygen to the micro-
organisms that breakdown the organic waste. Two main methods are used for this, either
mechanical agitation of the water so that air from the atmosphere enters the water, or by
introducing air into the tank through diffusers.
6
2.2 Chemical Unit Processes [4]
Chemical unit processes are always used with physical operations and may also be used with
biological treatment processes, although it is possible to have a purely physio-chemical plant
with no biological treatment. Chemical processes use the addition of chemicals to the
wastewater to bring about changes in its quality. They include pH control, coagulation,
chemical precipitation and oxidation.
2.2.1 PH Control
Waste from textile industries is rarely pH neutral. Certain processes such as reactive dyeing
require large quantities of alkali but pretreatments and some washes can be acidic. It is
therefore necessary to adjust the pH in the treatment process to make the wastewater pH
neutral. This is particularly important if biological treatment is being used, as the
microorganisms used in biological treatment require a pH in the range of 6-8 and will be
killed by highly acidic or alkali wastewater. Various chemicals are used for pH control. For
acidic wastes (low pH) sodium hydroxide, sodium carbonate, calcium carbonate or calcium
hydroxide, may be added among other things. For alkali wastes (high pH) sulphonic acid or
hydrochloric acid may be added. Acids can cause corrosion of equipment and care must be
taken in choosing which acid to use. Hydrochloric acid is probably better from an
environmental view point but can corrode stainless steel therefore plastic or appropriately
coated pumps and pipes must be used.
7
2.2.2 Chemical Coagulation and Flocculation
Coagulation is a complex process but generally refers to collecting into a larger mass the
minute solid particles dispersed in a liquid. Chemical coagulants such as aluminum sulphate
(alum) or ferric sulphate may be added to wastewater to improve the attraction of fine
particles so that they come together and form larger particles called flocs. A chemical
flocculent, usually a polyelectrolyte, enhances the flocculation process by bringing together
particles to form larger flocs, which settle out more quickly Flocculation is aided by
gentle mixing which causes the particles to collide.
2.3 Biological Unit Processes [4]

Biological treatment is an important and integral part of any wastewater treatment plant that
treats wastewater from either municipality or industry having soluble organic impurities or a
mix of the two types of wastewater sources. The obvious economic advantage, both in terms
of capital investment and operating costs, of biological treatment over other treatment
processes like chemical oxidation; thermal oxidation etc. has cemented its place in any
integrated wastewater treatment plant.
Biological treatment using aerobic activated sludge process has been in practice for well over
a century. Increasing pressure to meet more stringent discharge standards or not being
allowed to discharge treated effluent has led to implementation of a variety of advanced
biological treatment processes in recent years.
The objective of biological treatment of industrial wastewater is to remove, or reduce the

concentration of, organic and inorganic compounds. Biological treatment process can take
many forms (Table 2) but all are based around microorganisms, mainly bacteria.
Table 2-2: Biological Treatment Processes

Treatment Processes Definition
Suspended-growth processes e.g. activated The micro-organisms are maintained in
sludge suspension in the liquid
Attached-growth processes or fixed-film The micro-organisms are attached to some
processes inert medium such as rock or inert plastics
Combined processes A combination of suspended-growth
and fixed-film
8
These microorganisms use components of the effluent as their “food” and in doing so break
them down to fewer complexes and less hazardous compounds. In the process the
microorganisms increase in number.
Figure 2-1: Typical Flow Diagram of a Biological Treatment Plant

* A sludge recycle line is essential for activated sludge systems but is not needed for fixed film
systems. ** The aeration unit can be either activated sludge or a fixed film reactor.
There are two main types of processes, these involve suspended microbial growth (e.g.
activated sludge) and attached microbial growth (e.g. fixed film). With both approaches large
populations of microorganisms are brought into contact with effluent in the presence of an
excess of oxygen. In both systems the microbial population has to be retained in a tank
referred to as the reactor. With suspended growth systems microbes grow in small aggregates
or “flocs” (this is known as activated sludge).
2.3.1 Activated Sludge

Activated sludge (AS) leaves the reactor with the treated effluent but is settled out in a
clarifier and returned to the aeration unit to recycle the bacteria. If the amount of AS is
excessive some may be disposed of rather than being recycled.
2.3.2 Fixed Film

In fixed film systems the microbial population grows as a thin layer (a “bio-film”) on the
surface of an inert support medium. The classical fixed film system is known as a percolating
9
or biological filter and uses small stones as a medium to support microbial growth. In the
more modern system microbes grow on plastic supports. In the traditional percolating filters
effluent is sprayed over the medium and trickles through a packed bed with oxygen entering
from the air. In more recent reactor designs, the medium (usually plastic) is submerged in
effluent and air is blown into the base of the reactor. Submerged fixed film reactors using
plastic media require much less land. Fixed film systems require a final clarifier to remove
particles of biofilm that become detached from the medium.
Biological treatment plants must be carefully managed as they use live microorganisms to
digest the pollutants. For example some of the compounds in the wastewater may be toxic to
the bacteria used, and pre-treatment with physical operations or chemical processes may be
necessary. It is also important to monitor and control pH as adverse pH may result in death of
the microorganisms. The ETP must be properly aerated and must be operated 24 hours a day,
365 days a year to ensure that the bacteria are provided with sufficient “food” (i.e.
wastewater) and oxygen to keep them alive. Like humans, microorganisms need a “balanced
diet” with sources of carbon, nitrogen, phosphorus and Sulphur.
2.4 Physio-chemical Treatment

The basic units needed for a stand-alone physio-chemical treatment plant are screening, an
equalization unit, a pH control unit, chemical storage tanks, a mixing unit, a flocculation unit,
a settling unit and a sludge dewatering unit.
2.5 Physio-chemical and Biological Treatment

In this type of treatment a combination of physical operations, and physio-chemical and
biological processes are used. The basic units needed for a physio-chemical and biological
treatment plant are screening, an equalization unit, a pH control unit, chemical storage tanks,
mixing units, flocculation units, a primary settling unit, an aeration unit, and a secondary
settling unit. The physio-chemical unit always comes before the biological unit.
10
CHAPTER 3
PROGRAMMABLE LOGIC CONTROLLER ) PLC )

3.1 INTRODUCTION:
The programmable logic controller can be considered as solid state member of the computer Family.
A programmable logic controller is an industrial computer in which control devices such as limit
switch, push-buttons, proximity or photoelectric sensors, float switch, or pressure gauge temperature
switches, flow control switches, torque control switches, force control switches, counting control,
time keeping etc. provide incoming control signals into the unit. The incoming control signal is
called an input. A signal going out of the PLC to control a field device or output peripherals is called
an output.
Incoming control signals or inputs interact with the instruction specified in the user program either
in the form of statement or a ladder diagram, which tells the PLC how to react to the incoming
signals. The user program also direct the PLC on how to control field devices or output peripherals
like motor starters, motor speed, motor torque, motor rotational direction or position pilot lamps,
solenoids, conveyer belt movement, dimming light and many others.
The machine would use state inputs & output instead of control the motor starters åt sense push
buttons & limit switches.
3.2 DEFINATION:
Programmable logic controllers, also called programmable controller or PLCs, are solid-state
members of the computer family, using integrated circuits instead of electromechanical devices to
implement control functions. They are capable of storing instructions, such as sequencing, timing,
counting, arithmetic, data manipulation, and communication, to control machines and processes.
Programmable controllers have many definitions. However, PLCs can be thought of in simple terms
as industrial computers with specially designed architecture in both their central units (the PLC
itself) and their interfacing circuitry to field devices ( input/output connections to the real world ).
Fig 3.1: PLC conceptual application diagram
11
3.3 HISTRORICAL BACKGROUND OF PLC:
Automation of many different process, such as controlling machines or factory assembly lines, is
done through the use of small computers called a programmable logic controller (PLC). This is
actually a control device that consists of a programmable microprocessor, and is programmed using
a specialized computer language Before, a programmable logic controller would have been
programmed in ladder logic, which is similar to a schematic of relay logic. A modern programmable
logic controller is usually programmed in any one of several languages, ranging from ladder logic to
basic or C. Typically die program is written in a development environment on a personal computer
(PC), and then is downloaded onto the programmable logic controller directly through a cable
connection. The program is stored in the programmable logic controller I non-volatile memory.
In the late 1960's an American company named Bedford Associate released a computing device they
called the MODICON. As an acronym, it mean Modulator Digital Controller, and later became the
name of a company division devoted to the design, manufacture, and sale of these special-purpose
control computers, Other engineering firms developed their own versions of this device, and it
eventually came to be known in non-proprietary terms as a PLC, or Programmable Logic Controller.
The purpose of a PLC was to directly replace electromechanical relays as logic elements,
substituting instead a solid-sale digital computer with a stored program, able to emulate the
interconnection of many relays to perform certain logical tasks.
Programmable logic controllers were first created to serve the automobile industry, and the first
programmable logic controller project was developed in 1968 for General Motors to replaced hard-
wired relay system with an electronic controller. The commercially PLC was introduced in 1969.
During 1970s microprocessor based PLC was introduced with intelligent I/O devices & memories.
A PLC has many "input "terminals through which it interprets "high" and "low" logical states from
sensors and switches. IT also has many output terminals, through which it outputs "high" and "low"
signals tom power lights, solenoids, contactors, small motors, another devices lending themselves to
on/of control. In an effort to make PLCs easy to program, their programming language was designed
to resemble ladder logic diagrams. Thus, an industrial electrician or electrical engineer accustomed
to reading ladder logic schematics would feel comfortable programming a PLC to perform the same
control function.
3.4 BASIC PLC ARCHITECTURE:

The basic architecture of a PLC consists of main components the processor module, the poses
supply, and the I/O modules. The processor module consists of the central processing wait (СРС)
and memory. In addition to a microprocessor, the CPU also contains at just an interface to a
programming device and may contain interfaces to remote 10 and other communication networks.
The power supply is usually a separate module, and the I/O modules are separate from the
processor.
Fig 3.2: Block diagram of a simple Programmable Logic Controller (PLC)
12
3.4.1 MICROPROCESSOR:
The central processor unit (CPU) is a microprocessor system that contains the system memory and is
the PLC decision-making unit. The CPU monitors the inputs, outputs, and other variables and makes
decisions based on instructions held in the program memory. Typical CPU operations include relay,
counting, timing functions, data comparison, sequencing, and arithmetic operations. It receives the
input data from the input circuit and gets command or instructions from the program memory. Then
it performs arithmetic and/or logic functions in accordance with the programmed instructions and
produce outputs. These outputs are sent to the output circuit. A microprocessor can process a
number of inputs and produce a number of outputs simultaneously.
3.4.2 MEMORY:
A memory chips consists of a number of memory cells into which data bits may be stored. These
memory cells are grouped together to form a memory location (ie one-hit, tao-bit, four-bit etc). Data
stored in these locations are known as words. A word is a group of binary bits forming the basic unit
of information of a system. An eight-bit word is referred to as a byte. Each location is given a
unique binary code known as address for the purpose of acetification. There are several memory
Clements in PLC system.
• ROM: Read only Memory (ROM) is used for permanent storage of the operating
system and fixed data used by the manufacture. We can't write or store any data or
instruction into this memory. This type of memory is used to protect data or
programs from accidental crasure, ROM memory is nonvolatile. This means a user
program will not lose data during a loss of electrical power. ROM is normally used to
store the programs that define the capabilities of the PLC.
• RAM: Random Access Memory (RAM) is designed so that information can be

written into or read from the memory. Generally, PLC uses the CMOS-ROM with
battery support for user program memory Data RAM is used to store the status of the
input and output device and the value of timers, counters and other intermal devices.
If power fails then all data will be erased automatically. RAM is memory where data
can be directly accessed at any address. Duta can be written to and read from RAM.
RAM is used as a temporary storage area. RAM is volatile, meaning that the data
stored in RAM will be lost if power is lost. A buttery backup is required to avoid
losing data in the event of a power loss.
• PROM: Programmable Read Only Memory (PROM) is used to write program into
this memory only one time. PROM is a special type of ROM because it can be
programmed. Very few of today's programmable controllers use PROM for
application memory. When it is used, this type of memory is most likely a permanent
storage backup for some type of RAM. Although a PROM is programmable and, like
any other ROM, has the advantage of nonvolatility, it has the disadvantage of
requiring special programming equipment. Abe, once programmed, it cannot be
easily erased or altered; any program change requires a new set of PROM chips. A
PROM memory is suitable for storing a program that has bocce thoroughly checked
while residing in RAM and will not require further changes or on-line data entry.
13
• EPROM: Erasable Programmable Read Only Memory (EPROM) is designed so
that it can be programmed after being completely crashed with ultraviolet light
source by UVEPROMs(ultraviolet erasable programmable read only memory).
EPROM provides same level of security against unauthorized or unwanted changes
in a program. EPROMS are designed so that data stored in them can be read, but not
easily altered. Changing EPROM data requires a special effort.
• EEPROM: Electrically Erasable Programmable Read Only Memory (EEPROM)

is a nonvolatile memory that offers the same programming flexibility as RAM. It
provides permanent storage of the program but can be easily changed using standard
programming device. EEPROM can only be erased electronically.
• FIRMWARE: Firmware is user or application specific software burned into

EPROM and delivered as part of the hardware. Firmware gives the PLC its basic
functionality.
3.4.3 PROGRAMMING DEVICE:
Programs are entered into the PLC memory using a programming device that is usually not
permanently connected to a particular PLC and can be moved from one controller to another without
disturbing the operations. It allow the user to enter, edit and monitor programs by connecting into
the processor unit allowing access to the user memory Programming device can be a hand-held
device, a personal computer. A major advantage of using computer is that the program can be stored
on the hard disk or a floppy disk and copies easily made. When the program has been designed on
the programming device and is ready, it is transferred to the memory unit of PLC. To change the
programming device and is ready, it is necessary either to enter a new program directly from
keyboard or to download one from hard disk while online PLC can handle one program in memory
at a time.
3.4.4 INPUT AND OUTPUT SECTIONS:

The I/O section of a PLC consists of input output modules. The 1/0 system forms the interface by
which field devices are connection to the controller. The purpose of this interface is to condition the
various signals received from or send to external devices. Input devices such as push buttons, limit
switches, sensors, selector switch and analog signals are hard-wired to terminals on the input
modules. Output devices such as small motors, metor starters, solenoid valves, indicator lights and
final control elements (control valves) are hard-wired to the terminals on the output modules. Input
Interface modules accept signals from the machines or process devices (120v ac or 24v dc) and
convert them into signal (5v de) that can be used by the microprocessor. The following circuit
diagram shows the basic input circuit can be used by the discrete and digital inputs. Op to-isolators
can be used for protection.
3.5 THE GUTS INSIDE OF PLC:

The PLC mainly consists of a CPU, memory areas, and appropriate circuits to receive input/output
data. We can actually consider the PLC to be a hox full of hundreds or thousands of separate relays,
counters, timers, and data storage locations. Do these counters, timers, etc. really exist? No they
don't "physically" exist but rather they are simulated and can be considered software counters,
timers, etc. These internal relays are simulated through bit location in registers.
14
3.6 WORKING FUNCTION OF EACH PART OF PLC:
◆ INPUT RLAYS: These are connected to the outside world. They physically exist and
receiver signals from switches, sensors, etc. Typically they are not relays but rather they are
transistors.
◆ INTERNAL UTILITY RELAYS : These do not receive signals from the outside world
nor do they physically exist. They are simulated relays and are what enables a PLC eliminate
external relays. There are also some special relays that are dedicated to perforating only one task.
Some era always on while some are always off. Some are on only once during power-on and are
typically used for initialization data that was stored.
◆ COUNTERS: These again do not physically exist. They are simulated counters and they can
be programmed to count pulses. Typically these counters can count up, down or both up and down.
Since they are simulated they are limited in their counting speed. Some manufactures also include
high-speed counters that are hardware based. We can think of these as physically existing. Most
times these counters can count up, down or up and down.
◆TIMERS: These also do not physically exist. They come in many varieties and increments.
The most common type is an on-delay type. Others include off-delay and both retentive and non-
retentive types.
◆ DATA STORAGE: Typically there are registers assigned to simply store data. They are
usually used as temporary storage for math or data manipulation. They can also typically be used to
store data when power is removed from the PLC.
15
3.7 PLC OPERATION:
A PLC is continuously running through its program and updating on accordance of the input signals
Each such loop is called a cycle. During each operating cycle, the processor reads all the inputs,
takes these values, and according to the user program energizes or de energives the outputs. This
process is known as scan. A scan cycle is the time required for a PLC to scan all the inputs and
generate appropriate control response at its outputs. Scan time varies with program content and
length A scan can take from 1 to 20 ms.The updating sequence is thus as follows:
◆ Scan all the input and store into RAM

◆ Fetch, decode and execute all program instructions in sequence
◆ Copying all output instruction to RAM
◆ Update all outputs
Fig 4.3: PLC operation
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3.8 FEATURE AND ADVANTAGES OF PLC
PLC is more modem control system It has various feature and advantages. Sorse of these are given
below
◆ Easy to program
◆ On-line ON/OFF facility of inputs & outputs
◆ Does not suffer from fatigue problem
◆ Modulator plug-in construction available
◆ Cost effective
◆ Compact in construction
◆ Can be checked without field device
◆ Monitoring facilities available
◆ Can perform complex logic operation
◆ Self diagnostics for troubleshooting
◆ Faster system response
◆ Higher reliability
◆ Easy maintenance
◆ Can interface with computer
3.9 DISADVANTAGES OF PLC:
There are many disadvantages of PLC but we describe here only a few major disadvantages such as
◆ Newer Technology: This technology is never so to opened this need high skilled
. personal
◆ Fixed program Applications: Generally PLC includes multiple programming

capabilities so for a particular operation this is costly for use.
◆ Environmental Considerations: Certain process environments, such as high heat
and vibration, interface with the electronics devices in PLC x which limit their use.
◆ Fixed-circuit operation: If the circuit in operation is never altered, a fixed control
system mighty be less costly than a PLC, The PLC is most effective when periodic changes in
operation are made.
3.10 DIFFERNCE BETWEEN PLC &PC (PERSONAL COMPUTERS):
PLC PC
Environment The PLC was specially designed Common PCs are not designed
for harsh conditions with electrical for harsh environments.
noise, magnetic fields, vibration, Industrial PCs are available bui
extreme temperature or humidity. cost more.
Ease of Use By design PLCs are friendlier to Operating systems like Window
technicians since they are in ladder are common. Connecting 10 to
logic and have easy connections. the PCs is not always as easy.
Flexibility PLCs in rack form are easy to Typically PCs are limited by the
exchange and add parts. They are number of cards they can
17
designed for modularity and accommodate and are not easily
expansion. expandable.
Speed PLCs execute a single program in PCs by design, are meant to
sequential order. The have better handle simultaneous tasks.
ability to handle events in real They have difficulty handling
time. real time events.
Reliability A PLC never crashes over long A PC locking up and crashing is
periods of time. (NEVER may not frequent.
be the right word but its close
enough to be true.)
3.11 Requirement component of ZLD for PLC

3.11.1 Relay
A relay is an electrically operated switch Many relays use an electromagnet to operate a switching
mechanism mechanically, but other operating principles are also used Relays are used where it is
necessary to control a circuit by a low-power signal (with complete electrical isolation between
control and controlled circuits), or where several circuits must be controlled by one signal. The first
relays were used in long distance telegraph circuits. repeating the signal coming in from one circuit
and re-transmitting it to another. Relays were used extensively in telephone exchanges and early
computers to perform logical operations A type of relay that can handle the high power required to
directly control an electric motor or other loads is called a contactor. Solid-state relays control power
circuits with no moving parts, instead using a semiconductor device to perform switching Relays
with calibrated operating characteristics and sometimes multiple operating coils are used to protect
electrical circuits from overload or faults; in modem electric power systems these functions are
performed by digital instruments still called "protective relays".
Figure 2.1 Relay

3.11.2 Operation of Relay
A simple electromagnetic relay consists of a coil of wire wrapped around a soft iron core, an iron
yoke which provides a low reluctance path for magnetic flux, a movable iron armature, and one or
more sets of contacts (there are two in the relay pictured). The armature is hinged to the yoke and
mechanically linked to one or more sets of moving contacts. It is held in place by a spring so that
when the relay is de-energized there is an air gap in the magnetic circuit. In this condition, one of the
two sets of contacts in the relay pictured is closed, and the other set is open. Other relays may have
more or fewer sets of contacts depending on their function. The relay in the picture also has a wire
connection the armature to the yoke. This ensures continuity of the circuit between the moving
contacts on the armature, and the circuit track on the printed circuit board (PCB) via the yoke, which
is soldered to the PCB When an electric current is passed through the coil it generates a magnetic
field that activates the armature, and the consequent movement of the movable contacts) either
makes or breaks (depending upon construction) a connection with a fixed contact If the set of
18
contacts was closed when the relay was de-energized, then the movement opens the contacts and
breaks the connection, and vice versa if the contacts were open. When the current to the coil is
switched off, the armature is returned by a force, approximately half as strong as the magnetic force,
to its relaxed position. Usually this force is provided by a spring, but gravity is also used commonly
in industrial motor starters. Most relays are manufactured to operate quickly. In a low-voltage
application this reduces noise; in a high voltage or current application it reduces arcing.
When the coil is energized with direct current, a diode is often placed across the coil to dissipate the
energy from the collapsing magnetic field at deactivation, which would otherwise generate a voltage
spike dangerous to semiconductor circuit components. Some automotive relays include a diode
inside the relay case. Alternatively, a contact protection network consisting of a capacitor and
resistor in series (snubber circuit) may absorb the surge. If the coil is designed to be energized with
alternating current (AC), a small copper "shading ring" can be crimped to the end of the solenoid,
creating a small out-of-phase current which increases the minimum pull on the armature during the
AC cycle.
A solid-state relay uses a thyristor or other solid-state switching device, activated by the control
signal, to switch the controlled load, instead of a solenoid. An optocoupler (a light- emitting diode
(LED) coupled with a photo transistor) can be used to isolate control and controlled circuits.
3.11.3 Types of Relay
1.Latching relay
2. Reed relay
3.Mercury-wetted relay
4. Polarized relay
5. Machine tool relay
6. Ratchet relay
7. Contactor relay
8.Solid-state relay
9. Solid state contactor relay
10. Buchholz relay
11. Forced-guided contacts relay
3.11.4 Applications of Relay
1. Amplify a digital signal, switching a large amount of power with a small operating power
2. A telegraph relay, repeating a weak signal received at the end of a long wire.
3. Controlling a high-voltage circuit with a low-voltage signal, as in some types of modem or audio
amplifiers.
4. Controlling a high current circuit with a low-current signal, as in the starter solenoid of an
automobile.
5. Detect and isolate faults on transmission and distribution lines by opening and closing circuit
breaker(protection relay).
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Advantages of Relay
1. Relays can switch AC and DC, transistors can only switch DC

2. Relays can switch higher voltage than standard transistors.
3. Relays are often a better choice for switching large current (>5A).
4. Relays can switch many contacts at once.
Disadvantages of Relay
1. Relays are bulkier than transistors for switching small currents

2. Relays cannot switch rapidly (except reed relays), transistors can only
switch many times per second.
3. Relays use more power due to the current flowing through their coil.
4. Relays require more currents than many ICs can provide, so alow
power transistor may be needed to switch the current for the relay's
coil.
3.11.5 Solenoid Valve

A solenoid is an electromechanical device which allows for an electrical device to control the flow
of a gas or liquid The electrical device causes a current to fire through a coil located on the solenoid
valve. This current flow in turn results in a magnetic field which causes the displacement of a metal
actuator. The actuator is mechanically finked to a mechanical salve inside the solenoid valve. The
valve then change state, either opening or closing to allow a liquid or gas to either flow through or
be blocked by the solenoid valve A spring is used tr return the actuator and valve back to their
resting state when the current flow is removed.
3.11.6 Operation of Solenoid Valve

A common use for two way solenoid valves is in central heating. The solenoid valves are controlled
by an electrical signal from the thermostat to regulate the flow of heated water to the heating
elements within the occupied space. Such valves are particularly useful when multiple heating zones
are fed by a single heat source. Commercially available
solenoid valve for this purpose are often referred to as zone
valves.
In the paintball industry solenoid valve are usually

referred to simply as "solenoids". They are
commonly used to control a larger valve used to control the
propellant In the industry, "solenoid" may also refer to an
electromechanical solenoid commonly used to actuate sear.
Figure: Solenoid Valve
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3.12 Arduino add PLC based SCADA for water treatment plant
Collect analog date by the Arduino send then through Modbus rs485 to PLC and
show them on SCADA through Modbus rs232.
Things used in this project
3.12.1 Hardware components
Arduino UNO × 1
TIA Portal (WinCC) SCADA software × 1
XGB Ls PLC × 1
XG5000 Ls PLC software × 1
Ultrasonic Sensor - HC-SR04 (Generic) × 1
Liquid Crystal Display × 1
MAX485 TTL RS485 × 1
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9V 1A Switching Wall Power Supply × 1
RS-232 to USB × 1
Modbus Master Data Scanner
Arduino IDE
USB Mini
3.12.2 Summary
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PLC technology “Programming Control System” is quite an interesting and crucial type of
modern automation nowadays factories and industries. Due to emerge of this technology in
several decades ago but it‟s still one of the most used and practical kind of control system all
around the world.
SCADA “Supervisory Control and Data Acquisition “is a control system architecture
comprising computers, networked data communications and graphical user interfaces for high-
level supervision of machines and processes.
Nowadays, almost all of the simple and complicated industries have these types of automation
the two main part of any factory is the control system which here implemented by using PLC
and the supervisory or operational part which here designed by a computer-based SCADA
system.
We can apply this project to any water treatment plant it‟s a prototype based on its kind of
sensors but in case of using the industrial ones we can control the high scale water filtration
treatment plants.
This project designed of three levels the first one is the control level where the sensors collect all
the physical data like level and temperature and combine them together and send them via
industrial protocol to the PLC and the second level is the control level where the data processed
and execute by using the logic inside the PLC all the logics written according to the IEC 61131-3
and the supervisory level had done by suing industrial protocol and a SCADA system to show
the data to the operator in the remote control station.
The project is a mimic of the big actual industrial projects we can use this design to configure
and operate even maintenance and troubleshoot the large-scale project. The students who want to
work on this project will collect enough knowledge to be a good engineer in his real engineering
life.
Abbreviations
• PLC Programmable Logic Controller
• IDE Integrated development environment
• USB Universal Serial Bus
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• SCADA Supervisory control and data acquisition
• K1 Pump1 Relay
• K2 Pump2 Relay
• L1-L2 Ultrasonic Level Sensor1 and 2
• LPS Low Pressure Switch
• RTD Resistance Temperature Detector
• EMG Emergency
• RS485 Is a standard defining the electrical characteristics of drivers and receivers for use in
serial communications systems.
• RS232 Recommended Standard 232 is a standard originally introduced in 1960 for serial
communication transmission of data.
• HMI Human Machine Interface
• Modbus Modicum (now Schneider Electric) Bus
• RTU Remote Terminal Unit
• TIA Portal Totally Integrated Automation
• LCD Liquid-crystal display
• ACK Acknowledge
• TT Temperature transmitter
• NO-NC Normally Open – Normally Close
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Introduction
A programmable logic controller(PLC) or programmable controller is an industrial computer that
has been ruggedized and adapted for the control of manufacturing processes, such as assembly
lines, machines, robotic devices, or any activity that requires high reliability, ease of
programming, and process fault diagnosis. Dick Morley is considered as the father of PLC as he
had invented the first PLC, the Modicon084, for General Motors in 1968.PLCs can range from
small modular devices with tens of inputs and outputs (I/O), in a housing integral with the
processor, to large rack-mounted modular devices with thousands of I/O, and which are often
networked to other PLC and SCADA systems.
3.11.3 Problem Statement

Today’s highly increasing competitiveness over the industry demands high quality and most
consistent products with competitive price. To address this challenge number of industries
considering various new product designs and integrated manufacturing techniques in parallel
with the use of automated devices.
One of the remarkable and influential moves for getting the solutions of abovementioned
challenge is the industrial automation. Industrial automation facilitates to increase the
product quality, reliability and production rate while reducing production and design cost by
adopting new, innovative and integrated technologies and services.
Automation takes a step further mechanization that uses a particular machinery mechanism
aided human operators for performing a task. Mechanization is the manual operation ofa task
using powered machinery that depends on human decision making.
On the other hand, automation replaces the human involvement with the use of logical
programming commands and powerful machineries
Industrial Automation is the replacement with computers and machines to that of human
thinking. The word Automation gives the meaning „self-dictating‟ or “a
mechanism moves by itself‟ that derived from the Greek words Auto and Matos where auto
means self while Matos means moving.
In a brief, industrial automation can be defined as the use of

set technologies and automatic control devices that results the automatic operation and
control of industrial processes without significant human intervention and achieving superior
performance than manual control. These automation devices include PLCs, PCs, PACs, etc.
And technologies include various industrial communication systems.
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The main goal of this project is to develop a student attendance using PLC and SCADA systems.
There are four scopes that will be cover in this project. First of all is to design and implement the
philosophy of the water treatment plant specially doing the wiring and fix the malfunctioning of
the design, second thing is to getting used to the PLC logic like Ladder programming, the third
scop is to understand how to use industrial protocols like Modbus, finally design and implement
a SCADA system that combine all of these aspects in one screen.
3.11.4 Theoretical Framework:

XG5000 Ls ClickSoftware:
LS Industrial Systems (LSIS) scoria’s leading PLC manufacturer. With PLC series divided into
many different segments. From compact PLC to modular PLC, LS IS has appeared more and
more in the industrialization market.
Today plc247.com would like to share with you the XG5000 software used to program a number
of LS PLCs, including:
+ XGT: XGK CPUU, XGK CPUH, XGK CPUA, XGK CPUS, XGK CPUE, XGI-
Series, XGR-Series.
+ XGB, XGT Series: XBM, XBC, XEC.
XGB 5000 Interface
26
TIA Portal(Win CC) SCADA software:
With Totally Integrated Automation Portal (TIA Portal), you not only integrate the basic
software (SIMATICSTEP 7, SIMATIC WinCC, SINAMICS Start drive, SIMOCODE ES, and
SIMOTIONSCOUT TIA), but you also benefit from additional functionalities thanks to new
options like TIA Portal Multiuser Engineering and energy management with the SIMATIC
Energy Suite via a single interface. That’s what makes TIA Portal more than just an engineering
framework.
Fig: TIA Portal WinCC Interface
2. Modbus Master Data Scanner:
ModScan is a Windows application which operates as a Modbus master. It allows you to access
and change data points in a connected slave device using either the RTU or ASCII Transmission
mode. ModScan is ideally suited for quick and easy compliance testing of the modbus protocol
and its built-in display of serial traffic allows effective troubleshooting of field connections.
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Modbus Master Interface
3. Arduino IDE:
The open-source Arduino Software(IDE) makes it easy to write code and upload it to the board.
This software can be used with any Arduino board.
Refer to the Getting Started page for Installation instructions.
SOURCE CODE
Active development of the Arduinosoftware is hosted by GitHub. See the instructions for
building the code. Latest release source code archives are available here. The archives are PGP-
signed so they can be verified using this pokey.
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Arduino IDE Interface
3.11.5 Practical framework

1. Arduino:
is an open-source platform used for building electronics projects. Arduino consists of both a
physical programmable circuit board (often referred to as a microcontroller and a piece of
software, or IDE (Integrated Development Environment) that runs on your computer, used to
write and upload computer code to the physical board. The Arduino platform has become quite
popular with people just starting out with electronics, and for good reason Unlike most previous
programmable circuit boards, the Arduino does not need a separate piece of hardware (called a
programmer) in order to load new code onto the board – you can simply use a USB cable.
Additionally, the Arduino IDE uses a simplified version of C++, making it easier to learn to
29
program. Finally, Arduino provides a standard form factor that breaks out the functions of the
micro-controller into amore accessible package(1).
Arduino UNO
The Uno is one of the more popular boards in the Arduino family and a great choice for
beginners. We'll talk about what's on it and what it can do later in the tutorial.
1) Ultrasonic Sensor HC-SR04
Ultrasonic Sensor HC-SR04 is a sensor that can measure distance. It emits ultrasound at 40 000
Hz (40kHz) which travels through the air and if there is an object or obstacle on its path It will
bounce back to the module. Considering the travel time and the speed of the sound you can
calculate the distance.
The configuration pin of HC-SR04 is VCC(1), TRIG (2), ECHO (3), and GND (4). The supply
voltage of VCCis +5V and you can attach TRIG and ECHO pin to any Digital I/O inyour
Arduino Board.
30
HC-SR04
2) Liquid Crystal Display (LCD)
The Liquid Crystal library allows you to control LCD displays that are compatible with the
Hitachi HD44780 driver. There are many of them out there, and you can usually tell them by
the 16-pin interface.
Output of the sketch on a 16x2 LCD
The LCDs have a parallel interface, meaning that the microcontroller has to manipulate
several interface pins at once to control the display. The interface consists of the following
pins:
A register select (RS) pin that controls where in the LCD's memory you're writing data to.
You can select either the data register, which holds what goes on the screen, or an instruction
register, which is where the LCD's controller looks for instructions on what to do next.
A Read/Write(R/W) pin that selects reading mode or writing mode
An Enable pin that enables writing to the registers
8 data pins (D0 -D7). The states of these pins (high or low) are the bits that you’re writing to a
register when you write, or the values you're reading when you read.
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There's also a display contrast pin (Vo), power supply pins (+5V and
GND) and LED Backlight (Bklt+ and BKlt-) pins that you can use to power the
LCD, control the display contrast, and turn on and off the LED backlight,
respectively.
16x2 LCD
3) MAX485 TTLRS485
RS485 Module
RS-485 is one type of asynchronous serial communication protocol because there is no

synchronizing clock signal transmitted along with the data. RS-485 uses differential signaling to
transfer binary data from one device to another. Differential signaling worked by creating
differential voltage using 5V positive and negative. This differential signaling method has the
advantage in rejecting common mode noise.
RS-485 supports a maximum data transfer rate of30 Mbps. RS-485 also supports many slaves
with a single master. RS-485 protocol can have up to 32 devices connected.
In this project, we are going to implement RS-485 protocol in communication between two
Arduinos using MAX485module. This module uses 5V as operating
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RS485 Module Pinout
voltage and has pinout configuration as shown in the following table. RS-485
module as transmitter
In order to be used as a transmitter, RE pin and DE pin must be connected to 5V, and DI pin is
connected to TX. Data is sent from Arduino TX pin to module DI pin, then data will be sent
through AB.
RS-485 module as receiver
In order to be used as a receiver, RE pin and DE pin must be connected to GND, and RO pin is
connected to RX. Data received by AB will be sent to RO pin that is connected to Arduino RX
pin so the data can be read by Arduino.
RS-485 can be implemented into three types of serial communication system: simplex, half-
duplex, and full-duplex. But in this project, we are only implementing simplex and half-duplex.
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1. PLC
1) Features
The features of XGB system are as follows.
(1) The system secures the following high performances.
(a) High Processing Speed
(b) Max. 384I/O control supporting small & mid-sized system implementation
(c) Enough program capacity
(d) Expanded applications with the support of floating point
XGB PLC Features
Input &Output wiring terms
Sink Logic
For a sink logic, an NPN transistor provides a path to ground for the electrical load. For an NPN
transistor circuit to work, it must be connected to a PNP transistor circuit. In other words, a sink
logic circuit needs to be connected to source logic circuit.
Figure 1 shows a sinking digital output that is connected to a sourcing digital input. The input
circuit is connected between the positive power supply side (Vcc) and NPN transistor.
Source Logic
For a source logic, a PNP transistor provides a path to voltage for the electrical load. For aPNP
transistor circuit to work, it must be connected to a NPN transistor circuit. In other words, a
source logic circuit needs to be connected toa sink logic circuit.
34
Figure 2 shows a sourcing digital out put that is connected to a sinking digital input. The input
circuit is connected between the PNP transistor and power supply GND (0v).
Sink and Source Wiring
1) XBG system configuration
XGB series System Configuration is as follows. Expanded I/O module and special module are
available to
connect maximum 7 stages for “S” type and 10 stages for “H” type. Expanded communication
module is available
to connect maximum 2 stages
35
XGB System Configuration
2) Downloadable
PLC communication may require various cables and connections fromRS232 serial, to Micro
USB, to Cat5e Ethernet. A range of specialized Communication cables is
36
available for PLC programming and I/O expansion. Since CPUs provide many different
communications port possibilities, it is helpful
to know exactly which communications cable is required. LS PLC
XGB Series PMC-310SLoader Cable Connection cable (PC to
PLC), 9pin-6pin.
Alternative Option was used USB as a download cable due to unavailability

of this special cable
3) Names of Part and Functions
Project Philosophy
First of all this project designed to be part of water treatment plant, as we can see in the figure
below that we have two main tanks in this project the tank on the left
37
called Tank1 and the one on the right called Tank2 all the process will doby using tank1 like the
federation and level controlling. Regarding to the storage tank on the right we can storage the
water after doing the process in the Tank2 for the further use.
As Built diagram and schematic
Level calculation
We have used two ultrasonic sensors to calculate the level of each tank because the PLC don‟t
have any analog input, we added these sensors to add more options to our project and its part of
stability and acuity.
Ultrasonic Level Sensor
The final installation shown in the figure below
38
Ultrasonic Level Sensors Installation
sensor number 1 called Level1 or L1 on the on-built drawing and its position on the tank
1tomeasure its level and the L2 is a level transmitter of the tank 2. according to the logic inside
the PLC the L1 make sure that Tank1 is full of water before starting the filtration process and L2
is make sure that we have water whatever the amount was before starting the pump. Also both of
these sensors take part in the turning off the pumps. When level of water become shallow some
timer inside the PLC start counting to turn of the specific pump.
39
Water circulation process
Circulation Pumps Installation
Water circulation process is one of the crucial parts of this project we’ve used two pumps to
fill or suck the water from the tanks and their positions showing in the figure below
The attached filter and its pump to the Tank1 is the main processing unit available in this
project and they have a Low-Pressure Switch or LPS and it prevent the pump to work without
water during the processing phase.
40
Filtration Pump, Filter and LPS
Local Control Panel

An industrial plant should have a local control panel that can control some processing options
form the field so in this scenario we added such a cool control panel to give an option for
controlling the process locally without the SCADA system, we can choose either remote or local
process by selecting from a remote switch on the SCADA main screen.
Local Control Panel
How it works
The plc continuously checks all sensors and will be ready to perform if there areno emergency or
error. The benefit of emergency pushbutton is use for shouting down the
41
entire plant and being in the alarm more till the emergency get to its normal position. The
acknowledge pushbutton can be used reset all the programs inside the PLC like timers and other
codes. The RUN indicator shows that the process in so doing, but the alarm indicator show both
errors and emergency by different blinking speed. by using the selector we can choose either
filtration process or refill after selecting the proper process we can press start to perform the
logic and stop to cancel the logic even in the middle of the process.
The PLC will work like this according to the logic inside
• · Check the water level in the Tank1
• · Check the selector position
• · Check the remote/local status of the SCADA
• · If the local control was selected and there is no alarm the pump will start
• · After 1.5 minute the PLC will check the LPS for the pressure
• · After 2.5 minute the PLC will turn off the pump and run the pump1
• · When the level in Tank1 reach the shallow level pump1will turn off
• · If the selector was in the Refill position and the operator pressed start
• · The PLC will drain the storage tank to the Tank1
• · If the PLC temperature exceed the limit of 35C the cooling fan will start
4. The temperature – fan diagram

This fan has been designed to prevent the PLC from overheating and its controlled by a TT
temperature transmitter connected to the Arduino and all the data transferred by Modbus
protocol to the PLC to take control of the fan if the temperature rose above 35C it will run the
cooling fan and if the temperature was or will be under 35 Cit will turn it off.
42
TT & Fan Schematic
PLC to SCADA RS-232

use only 3 pins to connect PLC with PC (SCADA)
RS232 to USB Cable
43
Schematics
The wiring of the PLC I/O
44
The mapping of the RS-232 (PLC-SCADA)
45
CHAPER-4
4 INTRODUCTION OF ZLD IN BANGLADESH
The textile sector is the backbone of Bangladesh’s economy. However, the industry is faced
with many challenges due to high resource (energy, water and chemical) footprint and its
consequent environmental impact. Water usage by the textile industry in Bangladesh is
estimated to be 1,500 million cubic meters, which is principally made of groundwater.
Around 70% of this water consumption takes place in the wet processing of textiles, which
involves washing, dyeing, and finishing of textiles. Besides high water footprint, the textile
industry also faces the challenge of dealing with the problem of effluent discharge and the
use of coagulants and chemicals for its treatment.
Realizing the scale of these issues and the urgent need for addressing them, Bangladesh
Government has issued the Zero Liquid Discharge (ZLD) Regulation for the textile sector.
This poses a huge challenge for the industry, particularly for the small and medium sized
units. The key to its successful implementation would be a cautious and practical approach
and view this as an opportunity to deal with the pressing environmental challenges in a
sustainable manner [6].
4.1 Reasons to Introduction of ZLD in Bangladesh

Reasons behind, why Zero Liquid Discharge (ZLD) technology should introduced in
Bangladesh as soon as possible are listed below:
4.1.1 Ground Water Level

Like many natural resources, groundwater is being exploited at an increasing rate all over the
world. Groundwater is generally preferred as a source of potable water in the developing
world because of its ready availability and natural protection from contamination. It is
commonly used for irrigation and to supply industrial and domestic needs. A lack of proper
understanding of the groundwater system, in terms of resource utilization, is one of the major
limitations to the effective management of groundwater resources [7].
Dhaka is dependent primarily on groundwater for the urban water supply; about 84% of the
present municipal water supply comes from groundwater and 16% is from surface water [8].
The dependence on groundwater for domestic, industrial, and commercial water supply in the
city area was more than 95% prior to the commissioning of a large surface water treatment
plant (Saidabad Surface Water Treatment Plant) in 2002.
46
The capital’s groundwater levels are falling rapidly due to excessive extractions to meet the
needs of its growing population, said Dhaka Water Supply and Sewerage Authority. The
capital’s underground water level has dropped to 60 meters below ground level, according to
DWASA. In 2011, the capital’s ground water level was 51 meters below the ground level,
according to a study of Bangladesh Agricultural Development Corporation. The groundwater
levels in the capital are falling by two to three meters each year, according DWASA [9].
4.1.2 National Standards for Wastewater

Effluent from textile dyeing industries must meet the national effluent discharge quality
standards set by the Government of Bangladesh, including the “Quality Standards for
Classified Industries” (Table 3-1), and may also need to meet additional standards set by
international textile buyers. Consequently any ETP must be designed and operated in such a
way that it treats the wastewater to these standards [10].
Table 3-1: Discharge Quality Standard for Classified Industries - Composite Textile Plant
and Large Processing Units
Parameter Limit, Bangladesh Standard (mg/L)
pH 6.5-9
Total Suspended Solid (TSS) 2100
Total Dissolved Solid (TDS) 100
Biochemical Oxygen Demand for 5 days 50
(BOD5)
Chemical Oxygen Demand (COD) 200
SO42- 400
S2- 2
Total Chromium 2
Phenolic Compounds 5
The regulations state that these quality standards must be ensured from the moment of going
into trial production for industrial units. They also state that the Department of Environment
can undertake spot checks at any time and the pollution levels must not exceed these quality
standards. Furthermore, the quality standards may be enforced in a more stringent manner if
considered necessary in view of the environmental conditions of a particular situation [11].
47
The waste discharge quality standards differ according to the point of disposal. So, the
standards are different for inland surface water (ponds, tanks, water bodies, water holes,
canals, river, springs or estuaries); public sewers (any sewer connected with fully combined
processing plant including primary and secondary treatment); and irrigated land defined as an
appropriately irrigated plantation area of specified crops based on quantity and quality of
wastewater [11].
Bangladesh Government is planning to lower the current limiting standards such as BOD
level to 30 mg/L from 50 mg/L, COD level to 150 mg/L from 200 mg/L. But with current
technology this is not possible to attain such result, so improvement of technology and
current process must be introduced.
4.2 Benefits and Challenges Facing the ZLD

While successful implementation of ZLD in the textile sector in Bangladesh would have
significant environmental, economic and social benefits, it is also thwart with many
challenges. It is important that before the ZLD mandate is rolled out in Bangladesh, the
regulatory authorities and the industry are fully aware of the pros and cons of such a program
in terms of the possible benefits and the challenges or roadblocks that can come in the way of
its successful implementation.
4.2.1 Benefits of ZLD

Implementation of ZLD had encouraged the industry to closely monitor water usage, avoiding
of wastages and to promote recycling. For example, the textile dyeing industry moved from
conventional Winches which used more water (1:16 Liquor of Fabric weight to Water volume)
to less water consuming Soft Flow Machines with 1:8 Liquor ratio and many are increasingly
moving towards even lower water consuming “Air flow Machines” with 1:3.5 Liquor ratios to
increase their production while generating lower volumes of effluent.The high recovery of
water (>90-95%) and the recovery of salt has mitigated the higher cost of operation of a ZLD
system.The implementation of ZLD paved the way for a more sustainable growth of the
industry while meeting most stringent environmental norms.Reduction in water demand from
the Industry by implementation of ZLD enabled in freeing up water for Agriculture and
Domesticdemands.
48
The environmental problems created earlier has been arrested and the degraded land and water
bodies are slowly recovering back Sustainable growth of the industry also implies growth in
economy and sustainable livelihood for many people who are dependent on the textile dyeing
cluster either directly or indirectly.
4.2.2 Challenges of ZLD

▪ ZLD results in generation of hazardous solid wastes (particularly waste mixed salt)
causing disposal challenges, which is being stored in storage yards within the CETPs.
▪ For the chemical sludge, the best way to dispose it off is its gainful utilization for
cement co-processing but it needs tie up with a willing/recipient cement company.
▪ The high cost of operation of a ZLD is also a major challenge. The recovery of water
and salt (Sodium sulphate and brine) offsets this costs significantly, but it would apply
only to water scarce areas where the cost of water is high.
▪ High Carbon foot print of a ZLD facility is another major concern. The typical power
consumption ranges from 8 to 10 kW/m3. The thermal evaporators alone consume about
20-40 kW/m3 in addition to several tons of firewood for the boilers.
▪ Non uniform application of ZLD standards across the country for similar industries
has serious impact on the competitiveness of the local industry.
▪ Implementation of ZLD requires a host of advanced wastewater treatment technologies.

Implementation of ZLD in Tamilnadu has highlighted several Technology shortcomings
such as in Thermal evaporation & brine concentration, Salt separation and
Crystallization, Color removal etc.
49
CHAPTER 5
5 OVERVIEW ON ZERO LIQUID DISCHARGE
Zero Liquid Discharge (ZLD) represents the ultimate cutting-edge treatment system for the
total elimination of wastewater effluent into neighboring waterways. The ZLD System
removes dissolved solids from the wastewater and returns distilled water to the process
(source). Reverse osmosis (membrane filtration) may be used to concentrate a portion of the
waste stream and return the clean permeate to the process. In this case, a much smaller
volume (the reject) will require evaporation, thus enhancing performance and reducing power
consumption. In many cases, falling film evaporation is used to further concentrate the brine
prior to crystallization [12].
Figure 4-1: General ZLD Technology Process
For over 30 years vapor compression evaporation has been the most useful technology to
achieve zero liquid discharge. Evaporation recovers about 95 % of a wastewater as distillate
for reuse. Waste brine can then be reduced to solids in a crystallizer/dewatering device.
However, evaporation alone can be an expensive option when flow rates are considerable.
One way to solve this problem is to integrate membrane processes with evaporation. These
50
technologies are nowadays often combined to provide complete ZLD-systems. The most
common membrane processes used so far are reverse osmosis (RO) and electro-dialysis
reversal (EDR). By combining these technologies with evaporation and crystallization ZLD-
systems have become less expensive. They are however combined differently depending on
the circumstances, see chapter general guidelines. Together with these components, a variety
of other well-known water treatment technologies are used in ZLD-systems for pre-treatment
and polishing treatment [13]. These treatments are:
• pH adjustment
• de-gasifier
• mixed/separate bed
• oil/water separator
• neutralization
• oxidation (UV, ozone, sodium hypochlorite)
• dissolved air flotation (DAF)
• carbon adsorption
• anaerobic or aerobic digestion
The variation of ZLD-systems are, as previously mentioned, endless. Below, I have tried to
display a couple of ZLD-systems applied in different industries. The power plant system, see
figure 1, is the most general system, while the other two, see figure 2 and 3, are commercial
ZLD-systems from two water treatment companies.
5.1 Process Selection

The individual processing steps (and their abbreviations used in the illustration) of the five
conventional ZLD processing schemes for treating wastewater include:
• Reverse osmosis (RO)

• Lime softening (LS)
• Thermal brine concentrator (BC)
• Thermal crystallizer (CRYST)
• Spray dryer (SD) (used only for low-volume flows)
• Evaporation pond (EP)
• Landfill (LF)
51
Product water is produced by the RO, BC, and CRYST process steps. Processing steps for the
wastewater treatment, beginning with concentrate (conc.), are as follows [14]:
• Scheme 1A: conc. → BC → EP

• Scheme 1B: conc. → BC → CRYST → EP
• Scheme 2A: conc. → LS → RO → BC → EP
• Scheme 2B: conc. → LS → RO → BC → CRYST → EP
• Scheme 3: conc. → LS → RO → EP
Solids produced from the lime softening and crystallization steps go to a landfill.
If the water flow rate is small, not many components are necessary. The following general
guidelines are accepted today [13]:
• Below 10 gpm of feed – crystallizers and/or spray dyers can be combined.

• 10 – 50 gpm of feed – use a crystallizer alone.
• 50 – 100 gpm of unsaturated feed – use an RO/EDR/crystallizer combination.
• 50 – 100 gpm of saturated feed – use an evaporator/crystallizer combination.
• 100 – 500 gpm of feed – either an RO/crystallizer or an evaporator/crystallizer
combination may be the most economical.
• 500 – 1000 gpm of feed – all three should be used
Figure 4-2: Zero liquid discharge system flow diagram
52
Figure 4-3: Example of how a present ZLD-system is integrated in a power plant
53
5.2 Some ZLD Process Examples:
5.2.1 Ionics’ EnChem. A ZLD-solution for the semiconductor industry
Ionic claims that their water treatment system, the EnChem, removes more than 99% of the
contaminating materials. The EnChem technology is also capable of reducing water usage
during the semiconductor manufacturing process by up to 85% through reclaim. Ionics’
EnChem technology is a low pressure water treatment solution. It is specifically designed to
reduce water consumption and operating costs [15].
Figure 4-4: Ionics’ ZLD-system for the semiconductor industry

The water to be treated has to go through four steps; through the reaction tank, on to the
filtration, on to the backflush and finally to de-watering. Each step is described below:
Step 1. Reaction step. Influent waste water is pH adjusted, then mixed with organic and
inorganic coagulant additives. The polymers react with the contaminants to form spheres. The
reaction is complete in a few minutes.
Step 2. Filtration. The filtration is accomplished through low pressure membranes. The clean
water then exits the top of the filter while solids are retained on the filter membrane.
Operating pressures remain below 15 psi (1 bar).
Step 3. Backflush. The membranes are pulsed to remove solids and then solids are pumped to
a settling tank.
Step 4. Solids formation/De-watering. Solids are pumped to a holding tank for further
settling. Conventional filter presses can be used to further separate and de-water solids.
Overflow filter press water is returned to the reaction tank.
54
5.2.2 Tenergys’ plating waste water recovery system
This ZLD-system is used for the Ni and Cr plating industry. Filtration is combined with
separated bed and an evaporator. The system can handle flow rates of 50 gpm.
Figure 4-5: Tenergys’ ZLD-system for the plating industry

In the pre-treatment step ultrafiltration (UF) is combined with carbon filter. UF is used for
removal of volatile organics, virus and bacteria and suspended solids. The carbon filter
contain granular activated carbon media that adsorb impurities within molecule-sized pores.
Oxidants such as chlorine are also removed during their interaction with the carbon surface.
After pre-treatment the water passes through the polishing step, which consists of separate
bed demineralizers, where the salts in the water are separated into positively charged cations
and negatively charged anions. The process begins when the water is passed through cation
exchange resin. The cation resin is in the hydrogen form (H+) and exchanges all the positively
charged ions for hydrogen, thus converting all the impurities in the water into acids. The
water from the cation exchange is then passed through anion exchange resin. Separate bed
means that there are two tanks, one containing cation resin, and the other containing anion
resin. The anion resin is in the hydroxyl form (OH-) and exchanges all the negatively charged
ions into the hydroxyl form, completing the conversion of all impurities into water (H+ + OH-
→ H2O), thus providing pure demineralized water.
The concentrates finally feed an evaporator providing clean water for plating, thus
completing the closed ZLD-system.
55
CHAPTER 6
6 ACHIEVING ZLD: EQUIPMENT OVERVIEW
6.1 Reverse Osmosis (RO)

Reverse osmosis is a process where water is pressurized so that it passes through a semi-
permeable membrane, leaving dissolved inorganic salts and silica behind. As a rough guide to
performance, RO can produce a concentrate containing 30000 ppm total dissolved solids
(TDS). Two problems with RO are that organics will seriously foul RO systems and that RO
requires a feed stream that is free of suspended solids. Because of this it is advisable to
remove organics from wastewater before it enters the RO, so extensive front-end filtration
equipment is required. Some membranes are pH and temperature sensitive, so pH control and
feed equalization may be necessary. RO is also quite energy-intensive. The advantage of RO
over evaporation is that the life cycle costs of RO are about half those of evaporators.
Figure 5-1: Industrial Reverse Osmosis Process
56
6.2 Electro-dialysis reversal (EDR)
Electro-dialysis reversal (EDR) is a membrane process in which electrolytes migrate across
charge-selective membranes in response to an electrical field. In EDR, the polarity of the
electrodes is reversed several times an hour and the fresh water and the concentrated
wastewater are exchanged within the membrane stack to remove fouling and scaling. EDR
differs from RO in that the ions are removed and the water is left behind, whereas in RO, the
water is removed and the ions are left behind. Because of this, silica and dissolved organics
are not removed with an EDR process, which is an important aspect to remember when the
clean stream is reused. Like RO, EDR requires solids and organics removal from the feed for
reliable operation.
Figure 5-2: Industrial Electro-dialysis reversal system
6.3 Evaporator
Evaporators come in all sizes and shapes, for example; falling film-, rising film-, forced
circulation and scraped surface/thin film- and combination evaporator. Evaporators produce a
distillate stream that is very clean, typically containing less than 10 ppm of TDS one of the
main reasons why evaporators are used in a ZLD-system. The most prevalent type is the
57
falling film evaporator, also called brine concentrator, see figure 4. This evaporator can treat
RO or EDR concentrates to a total solids (TS) concentration of 300 000 ppm. At this value
the boiling point rise of the brine results in either an excessively large heat-transfer area
(large capital cost) or an excessively large temperature difference (large operating cost).
Values higher than this makes the combination of a crystallizer and an evaporator more
economical than an evaporator alone.
Figure 5-3: A falling film evaporator, also called a brine concentrator [16]
58
6.4 Crystallizer
Figure 5-4: The heat flows in a crystallizer

The crystallizer reduces highly saturated wastewater to dry solids for disposal. High purity
water is recovered from the crystallizer for recycling. A crystallizer may also recover specific
salts from a mixed salt waste stream. The crystallizer is a forced circulation evaporator which
uses a mechanical vapor compressor or plant steam as the energy source.
6.5 Spray Dryer

When a crystallizer is not appropriate, the spray dryer is another method for dewatering the
concentrated slurry left over from the brine concentrator. The spray dryer transforms the
slurry into a fine powder of mixed salts for disposal. The spray dryer atomizes the wastewater
slurry inside a hot chamber, instantly vaporizing the water droplets and leaving only dry salts
behind.
59
CHAPTER 7
7.1 INTRODUCTION
The exact number of textile industries in Bangladesh could not be verified. According to WRG (2015)
report, the number of wet processing textile units is in the range of 500-700. It has been found that
around 241 Dyeing-Printing-Finishing Textile Mills are registered with the Bangladesh Textile Mills
Association (www.btmadhaka.com). The number of wet processing units is expected to increase
significantly over the next few years. It is estimated that around 70% of the Washing, Dyeing and
Finishing (WDF) textile processing units, which are responsible for a considerable portion of the water
demand and water pollution, are located in the Greater Dhaka area . The remaining units are located in
Mymensingh (north of Dhaka) and in Chittagong.
7.1.1 SUMMARY OF ZLD-ETP INDUSTRIES' INFORMATION

The information collected on industry type, capacity, water consumption, ETP and ZLD units, cost,
water reuse practices etc. and the laboratory test results of collected wastewater samples (according to
Figure 7.1) of selected twenty industries are summarized and presented in the following sub sections.
Water
Industry Production
Location Type of Industry consumption
Id Capacity
(Total)
Composite (Knitting,
Fatullah, Dyeing, finishing, Yarn
Z-1 20 ton/day 3000 m3/day
Narayanganj dyeing, Zipper Dyeing
and RMG)
Fatullah, Composite (Dyeing
Narayanganj and RMG)
Z-3 BSCIC,Narayanganj Dyeing 8-9 ton/day 600 m3/day
Rupgonj, Composite (Knitting,

Narayanganj Dyeing and Finishing)
Rupgonj,
Z-5 Dyeing& Finishing 120000Yards/day 300 m3/day
Narayanganj
Composite (Dyeing,
Z-6 Shafipur, Gazipur 22 ton/day 3000 m3/day
Finishing and RMG)
Couldn’t be
Z-7 Tongi, Gazipur Dyeing and Printing 6,00,000meter/day
determined
Composite (Knitting,
100000Metric
Z-8 Shafipur,Gazi pur Dyeing, Washing, 4870 m3/day
ton/day
Finishing)
Kashimpur, Composite (Knitting,
Konabari, Gazipur Dyeing and RMG)
Adamjee Washing
Z-10 20000pieces/day 370 m3/day
EPZ,Narayanganj and RMG
60
Figure 0.0: Industrial Clusters in Greater Dhaka Area (Sagris and Abott, 2015)
61
The information and test results of ETP industries are presented in following sub sections.
Water
Production
Industry Id Location Type of Industry consumption
Capacity
(Total)
Valuka, Dyeing, Washing

E-1 1,40,000Yards/day 4800 m3/day
Mymensing & Finishing
Konabari,
E-2 RMG Washing 20000 piece/day 1890 m3/day
Gazipur
Composite
Konabari,
E-3 (Knitting,Dyeing, 8 ton/day 768 m3/day
Gazipur
Washing,Finishing)
E-4 Tongi, Gazipur Dyeing, Washing 10-11 Ton Day 1200 m3/day
Tongi BSCIC,
E-5 Dyeing 4.5 ton/day 450-500 m3/day
Gazipur
Knitting, Dyeing,
E-6 Tongi, Gazipur 8 ton/day 806 m3/day
Finishing
E-7 Gazipur Dyeing 800-1000kg/day 5 m3/day
E-8 Tejgaon, Dhaka Washing 0.1- 0.2 ton/month 4-5 m3/day
Shyampur, Knitting, Dyeing,

E-9 10 ton/day 960 m3/day
Dhaka Finishing
1,50,000Yards
E-10 Gazipur Dyeing /day
2500 m3/day
62
7.3 PERFORMANCE OF ZLD-ETPs
To assess the performance of ZLD-ETPs in treating the wastewater, samples were collected at
the inlet and final outlet (Figure 7.1) of the industry and analyzed. The quality of individual
parameters of ZLD-ETP industries are presented in Figure 7.1 to 7.8.
C
H
A
P
T
E
R
C C C C C C C
1 H H H H H H H
Outlet Lower Limit=6 (ECR 1997) Upper Limit=9 (ECR 1997)
A A A A A A A
P P P P P P P
Figure 7.1: pH Comparison of Selected ZLD-ETP T Industries
T T T T T T
E E E E E E
From Figure 7.1, it has been found that the pH values of all ten industries’ effluent are within the
E
allowable range of pH (6 – 9) set by ECR, 1997. R R R R R R R
Among the ten industries, the treated effluent’s dissolved

1 oxygen
1 content
1 1 four 1industries
of 1 1
(Figure 7.2) are much below the minimum DO value set by ECR,97 (4.5 mg/L). Only two
63
industries satisfy the standard limit (ECR, 97) and four remaining industry’s DO value is just
below the minimum limit.
11
10
9
8
7
DO (mg/L)
6
5
4
3
2
1
0
Z1 Z2 Z3 Z4 Z5 Z6 Z7 Z8 Z9 Z10
Industry Code
Inlet Outlet Lower Limit=4.5 (ECR 1997)
Figure 7.2: Variation of DO Content of Selected ZLD-ETP Industries

Figure 7.3 shows the BOD5 of influent and effluent of ten ZLD-ETP industries. Among the ten
industries, nine industries comply with the allowable limit set by ECR,97 (50 mg/L), only one
industry fails to comply. Thus it is apparent that the ETPs of these nine industries are
performing well under the present operating conditions.
900
800
700
BOD5 (mg/L)
600
500
400
300
200
100
0
Z1 Z2 Z3 Z4 Z5 Z6 Z7 Z8 Z9 Z10
Industry Code
Inlet Outlet ECR (1997)Limit = 50
Figure 7.3: Variation of BOD5 Concentration of Selected ZLD-ETP Industries
Performance of the ETPS of these industries in reducing COD is also found to be effective
(Figure 7.4). Only two industries fail to comply with the corresponding Bangladesh standard
(200 mg/L) and rest of the industries are well below the ECR,’97 limit. The industry
64
designated with code Z5 failed to comply with both the corresponding BOD5 and COD
discharge standards of ECR ‘97. It should be noted that both the influent BOD5 and COD of
this industry are very high. The 20m3/hr capacity ETP, installed at the Z5 industry, is
inadequate for the treatment of its effluent having very high BOD5 and COD loadings
resultingfrom the dyeing and finishing activities.
4000
3500
3000
COD (mg/L)
2500
2000
1500
1000
500
0
Z1 Z2 Z3 Z4 Z5 Z6 Z7 Z8 Z9 Z10
Industry Code
Figure 7.4: Variation of COD Concentration of ZLD-ETP Industries
The total dissolved solids concentration (TDS) of the ZLD-ETP industries is shown in Figure
7.5. Five industries comply with the allowable value set by ECR, 97 (2100 mg/L) and five
industries fail to comply. Although the effluent TDS values are within the allowable limit,
TDS of these five industries effluent is higher than those of respective influent
concentrations. The main reason for non-compliance and higher TDS concentration in the
outlet is that, most of the industries use a number of chemicals usually of large amounts (e.g.,
PAC, Polymer, Polyelectrolyte, Decoloring agent, Lime, etc.) in the treatment process which
may reduce the organic load but generally increase the dissolved solids content.
11000
10000
9000
8000
TDS (mg/L)
7000
6000
5000
4000
3000
2000
1000
0
Z1 Z2 Z3 Z4 Z5 Z6 Z7 Z8 Z9 Z10
Industry Code
Figure 7.5: TDS Variation among the ZLD-ETP Industries
65
The Total Suspended Solids (TSS) of all the ten industries is much below the corresponding
ECR, 97 limits of 150 mg/L (Figure 7.6). The clarification and filtration (Sand, AC, MGF)
processes seem to be very effective in removing suspended particles.
500
400
TSS (mg/L)
300
200
100
0
Z1 Z2 Z3 Z4 Z5 Z6 Z7 Z8 Z9 Z10
Industry Code
Figure 7.6: TSS Variation among the ZLD-ETP Industries
Although the chloride concentrations of treated effluents are within the allowable limit of
ECR, 97 (600 mg/L) for all the ten industries, seven industries effluent concentration is
higher than their respective influent concentrations (Figure 7.7). The reason behind this is the
use of chloride based compounds in treatment process.
8000
7000
6000
Cl- (mg/L)
5000
4000
3000
2000
1000
0
Z1 Z2 Z3 Z4 Z5 Z6 Z7 Z8 Z9 Z10
Industry Code
Figure 7.7: Cl-Concentration of Selected ZLD-ETP Industries
Although ECR, 97 has no limit for Color and industries don't have to comply the Color
standard, the research team thinks that color is a significant indicator representing industrial
pollution. Figure 7.8 presents the influent and effluent color concentration of ten industries. It
has been found from the Figure 6.8 that the effluent color concentration is low for only those
66
industries that have less color content at the influent. Other industries have considerable color
(around 1000 Pt-Co units) even after treatment. Therefore, it is evident that existing
technologies are not so effective in removing color of the wastewater.
5000
4000
Color (pt-Co)
3000
2000
1000
0
Z1 Z2 Z3 Z4 Z5 Z6 Z7 Z8 Z9 Z10
Industry Code
Inlet Outlet
Figure 7.8: Color Comparison of Selected ZLD-ETP Industries
In addition to the comparative analysis of the performance of ZLD-ETPs for each water
quality parameters, variation of concentrations of influent and effluent quality of all ten of
these ZLD-ETPs have been provided in Tables 7.1 and 7.2.
67
Table 7.1: Influent characteristics of ten ZLD-ETP
industries
Concentration of inlet wastewater at Various Industries Range Standard Standard

Standard
(minimum - Limit Limit
Limit
Water maximum) from from
from
Quality Z1 Z2 Z3 Z4 Z5 Z6 Z7 Z8 Z9 Z10 ECR’97 ECR’97
ECR’97
Parameters (Inland (Public
(Irrigated
Surface sewerage
Land)
Water) system)
pH 7.51 7.4 9.83 8.98 10.07 10.54 11.56 10.99 9.74 7.88 7.4 – 11.56 6.0-9.0 6.0-9.0 6.0-9.0
Color (Pt- 78 - 4500
256 186 1150 4000 2340 484 4500 2650 3780 78 - - -
Co)
Turbidity 27.1 - 746
55.3 94.7 27.1 49.7 361 66.6 249 746 59.9 85.1 - - -
(NTU)
DO (mg/L) 0.31 0.16 0.09 2.73 0.19 5.14 0.81 1.0 0.08 5.59 0.08 – 5.59 4.5-8.0 4.5-8.0 4.5-8.0
BOD5(mg/L) 240 100 - 840 ≤ 50 (at ≤ 250 (at ≤ 1000 (at
116 104 160 720 187.5 700 140 840 100
20°C) 20°C) 20°C)
COD (mg/L) 541 228 328 816 3600 505 1232 561 1728 320 228 - 3600 ≤ 200 ≤ 400 ≤ 400
EC (µs/cm) 1772 1240 4520 13700 1264 2660 4410 2140 7870 540 540 - 13700 ≤ 1200 ≤ 1200 ≤ 1200
Cl- (mg/L) 180 390 150 7400 135 205 380 290 150 165 135 - 7400 ≤ 600 ≤ 600 ≤ 600
NH3-N 0.942 –
0.942 1 2.21 5.94 5.315 1.197 11.63 5.235 7.625 2.258 ≤5 ≤5 ≤ 15
(mg/L) 11.63
PO43-(mg/L) 1.38 0.325 0.95 0.147 0.298 0.299 4.74 1.5 4.82 0.058 0.058 – 4.82 - - -
TDS (mg/L) 1410 669 3402 10710 1021 1848 3756 1418 6226 341 341 - 10710 ≤ 2100 ≤ 2100 ≤ 2100
TSS (mg/L) 65 94 93 128 402 53 428 128 350 129 53 - 428 ≤ 150 ≤ 500 ≤ 200
From Table 6.1, it is observed that the concentration (minimum and maximum value) of all
parameters vary within a wide range. It also shows that the textile industries' wastewater is
heavily polluted with high organic load and solids content and very low dissolved oxygen.
Therefore, it can be said that this wastewater must not be discharged into the environment
without proper treatment to save the environment.
Table 6.2 shows the characteristics of treated effluent of ten ZLD-ETP industries. Among the
ten industries, most of them performed efficiently in removing BOD5, COD, TSS, Chloride,
PO34, and NH3-N. The performance of removing TDS and achieving DO according to the
ECR 97 limit is not quite satisfactory for many industries.
Table 7.2: Treated Effluent characteristics of ten ZLD-
ETP industries
Concentration at Various Industries Range Standard Standard
Standard
(minimum Limit Limit
Limit
Water – from from
from
Quality Z1 Z2 Z3 Z4 Z5 Z6 Z7 Z8 Z9 Z10 maximum) ECR’97 ECR’97
ECR’97
(Irrigated
Surface sewerage
Land)
Water) system)
pH 8.13 8.09 8.24 7.71 7.81 7.6 7.32 7.49 6.9 6.52 6.52 – 8.24 6.0-9.0 6.0-9.0 6.0-9.0
Color (Pt- 10 - 1150
125 87 55 920 400 284 1020 1150 310 10 - - -
Co)
Turbidity 0.72 – 60.2
14.9 9.04 11.2 8.23 60.2 11 4.36 5.58 25.5 0.72 - - -
(NTU)
DO (mg/L) 1.87 4.08 5.08 3.79 0.26 0.15 0.32 4.23 5.39 3.67 0.15 – 5.39 4.5-8.0 4.5-8.0 4.5-8.0
BOD5(mg/L) 10 0.4 - 140 ≤ 50 (at ≤ 250 (at ≤ 1000 (at
9.6 8 24 140 26 18 5 32.5 0.4
20°C) 20°C) 20°C)
COD (mg/L) 70 42 67 283 553 80 122 57 95 5 5 - 553 ≤ 200 ≤ 400 ≤ 400
EC (µs/cm) 2280 2460 1841 3590 1148 4550 4360 3330 5650 367 367 - 5650 ≤ 1200 ≤ 1200 ≤ 1200
Cl- (mg/L) 180 510 455 405 365 295 90 325 395 200 90 - 510 ≤ 600 ≤ 600 ≤ 600
NH3-N 0.338 – 3.06
0.338 1.69 0.55 1.05 1.5 3.06 1.712 1.295 0.483 0.465 ≤5 ≤5 ≤ 15
(mg/L)
PO43-(mg/L) 0.055 –
0.08 0.492 0.105 2.435 0.095 0.81 3.2 2.5 13.21 0.055 - - -
13.21
TDS (mg/L) 1542 1610 1184 2622 840 3173 3364 2289 4137 187 187 - 4137 ≤ 2100 ≤ 2100 ≤ 2100
TSS (mg/L) 8.13 8.09 8.24 7.71 7.81 7.6 7.32 7.49 6.9 6.52 7 - 72 ≤ 150 ≤ 500 ≤ 200
7.3 PERFORMANCE OF ETPs
The wastewater quality of individual parameters of industries running with ETPs only
(without ZLD plan) are shown in Figures 6.9 to 6.16.From Figure 6.9, it has been found that
the pH values of effluent of all ten industries are within the allowable range of pH (6 – 9) set
by ECR, 1997.
12
11
10
9
8
7
pH 6
5
4
3
2
1
0
E1 E2 E3 E4 E5 E6 E7 E8 E9 E10
Industry Code
Inlet Outlet Lower Limit=6 (ECR 1997) Upper Limit=9 (ECR 1997)
Figure 7.9: pH Comparison of among the studied ETP Industries
Among the ten industries with only ETP, the effluent dissolved oxygen contents of five
industries (Figure 7.10) are much below the minimum DO value set by ECR, 97 (4.5 mg/L),
whereas, five remaining industries satisfy the minimum requirement.
7
6
DO (mg/L)
5
4
3
2
1
0
E1 E2 E3 E4 E5 E6 E7 E8 E9 E10
Industry Code
Inlet Outlet Lower Limit=4.5 (ECR 1997)
Figure 7.10: Variation of DO Concentration of Selected ETP Industries
Figure 7.11 shows the BOD5 of influent and effluent of ten ETP (Only) industries. Among
these ten industries, eight industries comply with the allowable limit set by ECR,’97 (50
mg/L), and two industries fail to comply. Thus it is apparent that the ETPs of these eight
industries are performing well under the present operating conditions.
71
1200
1000
BOD5 (mg/L)
800
600
400
200
0
E1 E2 E3 E4 E5 E6 E7 E8 E9 E10
Industry Code
Figure 7.11: Variation of BOD5 Concentration of Selected ETP Industries
The performance of the industries with ETP in reducing COD is also found to be effective
(Figure 7.12). Only two industries fail to comply with the corresponding national standard
(200 mg/L) and rest of the industries are well below the ECR,’97 limit. The industries
designated with codes E4 and E6 failed to comply with both the corresponding BOD5 and
COD discharge standards of ECR ‘97. Since these two industries employ only physio-
chemical processes, it is difficult for these ETPs to treat wastewater having high BOD5 and
COD loadings resulting from the dyeing and finishing activities.
2000
COD (mg/L)
1500
1000
500
0
E1 E2 E3 E4 E5 E6 E7 E8 E9 E10
Industry Code
Figure 7.12: Variation of COD Concentration of Selected ETP Industries
The Total Dissolved Solids concentrations (TDS) of industries ETP (Only)are shown in
Figure 6.13. Seven industries comply with the allowable value set by ECR, '97 (2100 mg/L)
and three industries fail to comply. Although the effluent TDS values are within the
allowable limit, TDS of four of these ten industries treated effluents are higher than those of
respective influent concentrations. The main reason for non-compliance and higher effluent
concentration is that, most of the industries use a number of chemicals usually of large
amounts (e.g., PAC, Polymer, Polyelectrolyte, Decoloring agent, Lime, etc.) in the treatment
process which are capable of reducing the organic load but generally increase the dissolved
solids content.
6000
5000
TDS (mg/L)
4000
3000
2000
1000
0
E1 E2 E3 E4 E5 E6 E7 E8 E9 E10
Industry Code
Figure 7.13: TDS Concentration Variation of Selected ETP Industries
The TSS concentration of effluents of all the ten industries are within the limit of ECR, 97
(Figure 7.14).
600
500
TSS (mg/L)
400
300
200
100
0
E1 E2 E3 E4 E5 E6 E7 E8 E9 E10
Industry Code
Figure 7.14: TSS Concentration Variation of Selected ETP Industries
Although the chloride concentrations of treated effluent are within the allowable limit of
ECR, ‘97 (600 mg/L) for all the ten industries, eight of these industries show higher chloride
concentration in the treated effluent than those of the influents (Figure 7.15). The reason
behind this is the use of chloride based chemicals in treatment process.
Although ECR, 97 has no limit for Color and industries don't have to comply with the Color
standard, the research team thinks that color is a significant indicator representing industrial
pollution. Figure 6.16 shows the influent and effluent color concentration of ten ETP
industries.
700
600
500
Cl- (mg/L)
400
300
200
100
0
E1 E2 E3 E4 E5 E6 E7 E8 E9 E10
Industry Code
Figure 7.15: Variation of Cl- Concentration among ETP Industries
It has been found from the Figure 6.16 that industry E-10 is very effective in removing the
color (10 Pt-Co unit at the outlet sample) of its wastewater even though its influent color
concentration is more than 8000 Pt-Co Units. E-10 employs UASB technology in treating its
wastewater and it has been found from the study that this process is also capable of removing
other parameters effectively which agrees with the literature.
9000
8000
7000
Color (pt-Co)
6000
5000
4000
3000
2000
1000
0
E1 E2 E3 E4 E5 E6 E7 E8 E9 E10
Industry Code
Inlet Outlet
Figure 7.16: Color Variation of Selected ETP Industries
In addition to the comparative analysis of the performance of ETPs for each water quality
parameters, variation of concentrations of influent and effluent quality of all ten of these
ETPs have been provided in Table 6.3 and Table 6.4.From Table 6.3, it has been observed
that the minimum and maximum value of all parameters vary within a wide range, because of
wide variation of production capacity of the industries. Like ZLD-ETP industries, the ETP
industries' influent is also severely polluted with high organic load and solids content and
very low dissolved oxygen.
Table 7.3:Influent characteristics of ten ETP industries

Standard
Limit
Water – from from
from
Quality E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 maximum) ECR’97 ECR’97
ECR’97
(Irrigated
Surface sewerage
Land)
Water) system)
5.63 –
pH 11.51 7.03 9.5 9.15 7.77 7.72 7.68 5.63 6.85 11.52 6.0-9.0 6.0-9.0 6.0-9.0
11.52
Color (Pt- 53 - 8500
800 360 1700 1420 202 1396 1070 53 5500 8500 - - -
Co)
Turbidity 51 - 744
303 371 88.2 219 74.3 101 98.6 51 56 744 - - -
(NTU)
DO (mg/L) 0.31 5.64 0.11 0.1 0 0.05 0.08 4.25 5.21 0.05 0 – 5.64 4.5-8.0 4.5-8.0 4.5-8.0
BOD5(mg/L) 920 28 - 1160 ≤ 50 (at ≤ 250 (at ≤ 1000 (at
240 112 256 220 300 80 28 128 1160
20°C) 20°C) 20°C)
COD (mg/L) 1856 687 372 704 443 794 660 137 698 2078 137 - 2078 ≤ 200 ≤ 400 ≤ 400
EC (µs/cm) 3760 755 3700 4320 2710 7120 755 863 6320 7370 755 - 7370 ≤ 1200 ≤ 1200 ≤ 1200
Cl- (mg/L) 340 240 230 540 140 350 165 125 110 520 110 - 540 ≤ 600 ≤ 600 ≤ 600
NH3-N 0.468 –
0.468 1.462 1.994 2.09 0.539 2.025 2.77 1.23 11.5 14.46 ≤5 ≤5 ≤ 15
(mg/L) 14.46
PO43-(mg/L) 0.908 0.162 1.09 0.275 1.042 0.392 0.02 0.038 0.37 2.35 0.02 – 2.35 - - -
TDS (mg/L) 2736 678 2804 3302 2000 5550 634 601 708 1078 601 - 5550 ≤ 2100 ≤ 2100 ≤ 2100
TSS (mg/L) 242 586 240 226 72 231 36 93 124 396 36 - 586 ≤ 150 ≤ 500 ≤ 200
Table 7.4: Treated Effluent characteristics of ten ETP industries

Standard
Limit
Water – from from
from
Quality E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 maximum) ECR’97 ECR’97
ECR’97
(Irrigated
Surface sewerage
Land)
Water) system)
pH 7.32 6.99 7.72 7.12 7.4 7.43 7.3 7.64 7.47 7.48 6.99 – 7.72 6.0-9.0 6.0-9.0 6.0-9.0
Color (Pt- 10 - 820
32 110 148 335 113 231 85 13 820 10 - - -
Co)
Turbidity 1.2 – 57.4
8.62 14.3 8.62 57.4 33.2 25.2 4.07 1.29 23.9 1.2 - - -
(NTU)
DO (mg/L) 5.25 0.25 5.39 0.06 0.05 0.05 0.38 6.07 5.24 5.39 0.05 – 6.07 4.5-8.0 4.5-8.0 4.5-8.0
BOD5(mg/L) 0.4 - 220 ≤ 50 (at ≤ 250 (at ≤ 1000 (at
12.8 56 8 192 40 220 10 1.2 7 0.4
20°C) 20°C) 20°C)
COD (mg/L) 68 159 44 359 119 389 67 7 53 5 5 - 389 ≤ 200 ≤ 400 ≤ 400
EC (µs/cm) 2160 1235 1560 4090 2660 7000 1020 1533 3280 264 264 - 7000 ≤ 1200 ≤ 1200 ≤ 1200
Cl- (mg/L) 680 540 300 470 135 600 275 265 260 80 80 - 680 ≤ 600 ≤ 600 ≤ 600
NH3-N 0.224 – 2.9
0.469 1.103 1.17 0.457 0.652 2.9 1.275 0.567 1.825 0.224 ≤5 ≤5 ≤ 15
(mg/L)
PO43-(mg/L) 0.505 0.073 0.132 0.082 0.242 0.256 0.05 0.2 2.32 0.445 0.05 – 2.32 - - -
TDS (mg/L) 1354 858 1107 3051 1790 5224 775 989 2298 173 173 - 5224 ≤ 2100 ≤ 2100 ≤ 2100
TSS (mg/L) 43 28 35 60 45 28 42 15 27 11 11 - 60 ≤ 150 ≤ 500 ≤ 200
The performance of studied ETP industries in treating the wastewater can be termed as good
considering the removal efficiency of BOD, COD and TSS (Table 6.4).Whereas like ZLD-
ETP industries, these industries are not doing well in removing TDS and achieving minimum
DO content.
7.3 ASSESSMENT OF POLLUTION LOAD
Performance of an ETP depends not only on the physio-chemical and biological processes but
also largely on the pollutant loadings it has to endure. Usually, an ETP is designed for a
specific average and a peak flow and/or loading. Unfortunately, sustained high loading
endured by an ETP reduces its performance significantly. The loading rates of different
pollutants at ETPs of the ZLD-ETP and ETP (Only) industries are given in Tables 6.5 and 6.6
respectively.
Information collected from the ZLD-ETP industries show that Z-7 industry receives about
0.92 tons of pollutants exerting COD per day. Although it treats 90% of this load, it
discharges almost 2 tons of COD to the receiving environment every day. This factory
discharges about 13 tons of NH3-N, 25 tons of TDS, 0.25 tons of TSS, and 0.68 of chloride in
the receiving environment per day. In general, this industry fails to perform adequately to
achieve the objectives, but it performs very well in removing organic loading in the form of
BOD5, where it receives 5.25 tons and discharges only 0.13 tons in the receiving environment
every day.
Table 7.5: Influent and Effluent Loadings on Ten ZLD-ETP industries
Pollution Loading (kg/day)

Industry Code
NH3-N TDS TSS BOD5 COD Cl-
Inlet 2.261 3384 156 576 1298 432
Z-1
Outlet 0.811 3701 122 24 168 432
Inlet 0.64 428 60 74 146 250
Z-2
Outlet 1.082 1030 33 6 27 326
Inlet 1.768 2722 74 83 262 120
Z-3
Outlet 0.44 947 14 6 54 364
Inlet 28.512 51408 614 768 3917 35520
Z-4
Outlet 5.04 12586 96 115 1358 1944
Inlet 1.276 245 96 173 864 32
Z-5
Outlet 0.36 202 17 34 133 88
Inlet 3.95 6098 175 619 1667 677
Z-6
Outlet 10.098 10471 102 86 264 974
Z-7 Inlet 87.225 28170 3210 5250 9240 2850
Outlet 12.84 25230 255 135 915 675
Inlet 21.359 5785 522 571 2289 1183
Z-8
Outlet 5.284 9339 184 20 233 1326
Inlet 10.98 8965 504 1210 2488 216
Z-9
Outlet 0.696 5957 88 47 137 569
Inlet 0.361 55 21 16 51 26
Z-10
Outlet 0.074 30 1 0.1 1 32
Inlet 0.36 55 21 16 51 26
Minimum
Outlet 0.07 30 1 0.1 1 2
Inlet 87.23 51408 3210 5250 9240 35520
Maximum
Outlet 12.84 25230 255 135 1358 1944
Inlet 15.83 10726 543 934 2222 4131
Average
Outlet 3.67 6949 91 47.3 329 673
Information collected from the ETP industries show that E-1 industry receives the highest
amount of pollutants exerting COD per day (about 8.9 tons/day). However, it removes 96%
of COD load and discharges about 4% to the receiving environment every day. Performance
of E-1 industry in treating BOD5 loadings is significant removing 98.5% of received load. On
the other hand, E-10 industry receiving about 5 tons of pollutants exerting COD per day
removes 99.75% of the same. This factory also receives significantly high NH3-N loading (34
kg/day), successfully removing 98% of the same.
Table 6.6: Influent and Effluent Loadings on Ten ETP industries
Pollution Loading (kg/day)

Industry Code
NH3-N TDS TSS BOD5 COD Cl-
Inlet 2.246 13133 1162 4416 8909 1632
E-1
Outlet 2.251 6499 206 61 326 3264
Inlet 2.105 976 844 346 989 346
E-2
Outlet 1.588 1236 40 81 229 778
Inlet 1.914 2692 230 108 357 221
E-3
Outlet 1.123 1063 34 8 42 288
Inlet 2.508 3962 271 307 845 648
E-4
Outlet 0.548 3661 72 230 431 564
Inlet 0.453 1680 60 185 372 118
E-5
Outlet 0.548 1504 38 34 100 113
Inlet 1.458 3996 166 216 572 252
E-6
Outlet 2.088 3761 20 158 280 432
Inlet 0.042 10 1 1.2 10 2
E-7
Outlet 0.019 12 1 0.2 1 4
Inlet 0.006 3 0 0.1 1 1
E-8
Outlet 0.003 5 0 0 0 1
Inlet 13.8 850 149 154 838 132
E-9
Outlet 2.19 2758 32 8 64 312
Inlet 34.704 2587 950 2784 4987 1248
E-10
Outlet 0.538 415 26 1 12 192
Inlet 0.01 3 0.47 0.14 0.69 0.63
Minimum
Outlet 0.00 5 0.08 0.01 0.04 1.33
Inlet 34.70 13133 1162 4416 8909 1632
Maximum
Outlet 2.25 6499 206 230 431 3264
Inlet 5.92 2989 383 852 1788 460
Average
Outlet 1.09 2091 47 58 149 595
7.7 ANALYSIS OF BASELINE DATA OF SELECTED INDUSTRIES
The industries selected in the present study vary in size (area), investment cost, production
capacity, type and also the wastewater treatment technology. Table 6.7 shows the information
collected on individual industry and Table 6.8 shows a summary of the studied industries
regarding their production capacity, water use, ETP capacity and adopted technologies to
treat the wastewater.
Table 7.7: Information on Selected Industries
ETP
Industry Production Industry Type Water ETP Investment Treatment
ID Capacity Consumption capacity cost Technology
(BDT)
Composite
(Knitting, Physico-
3
Z-1 Dyeing, 3000 m /day 2400 Chemical
20 ton/day finishing, Yarn m3/day 10 Crs followed by
dyeing, Zipper biological
Dyeing and
RMG)
Physico-
Composite
Z-2 6 ton/day 800 m3/day 640 90 Lacks Chemical
(Dyeing and
m3/day followed by
RMG)
biological
Physico-
Z-3 8-9 ton/day Dyeing 600 m3/day 800 2 Crs Chemical
m3/day followed by
biological
ETP
(BDT)
Composite Physico-
Z-4 40 ton/day (Knitting, 6044 m3/day 4800 4 Crs Chemical
Dyeing and m3/day followed by
Finishing) biological
Physico-
Z-5 120000 Dyeing& 300 m3/day 240 70-80 Lacks Chemical
Yards/day Finishing m3/day followed by
biological
Composite
Z-6 22 ton/day (Dyeing, 3000 m3/day 3300 6 Crs SBR+Physico-
Finishing and m3/day Chemical
RMG)
6, 00,000 Dyeing and 7500
Z-7 meter/day Data Not m3/day 170 Crs Biological
Printing
Found
Composite
100000
(Knitting, 4080 Biological
Metric
Z-8 Dyeing, 3
4870 m /day m3/day 6 Crs Process
ton/day
Washing,
Finishing)
Composite
Physico-
(Knitting, 2900 m3/day 1440
chemical
Z-9 12 ton/day Dyeing and m3/day 3 Crs
followed by
RMG)
Biological
20.000 Washing and 280 Data Not Physico-

Z-10 pieces /day 370 m3/day m3/day
RMG Found Chemical
Dyeing, Physico-chemical
1,40,000 4800
E-1 Washing & 4800 m3/day 10 Crs followed by
Yards/day Finishing m3/day biological
20,000 RMG Washing 1890 m3/day 1440 Physico-
E-2 pieces/day m3/day 2 Crs
Chemical
Composite
(Knitting, 960 Physico-chemical
E-3 8 ton/day Dyeing, 3
768 m /day m3/day 3 Crs followed by
Washing, Biological
Finishing)
Dyeing,
10-11 1200 m3/day 1200 Physico-
E-4 ton/day Washing m3/day 2.5 Crs
Chemical
450-500
4.5 ton/day 840 Physico-
E-5 Dyeing m3/day 1.2 Crs
m3/day Chemical
Knitting,
720 Data Not Physico-
E-6 8 ton/day Dyeing, 806 m3/day m3/day Found Chemical
Finishing
15 Physico-
E-7 1 ton/day Dyeing 5 m3/day m3/day 40 Lacks
Chemical
E-8 0.1-0.2 ton Washing 4-5 m3/day 5 m3/day 25-30 Lacks Electro-
ETP
(BDT)
/month Chemical
Knitting,
Physico-chemical
E-9 10 ton/day Dyeing, 960 m3/day 1200 2.5 Crs
followed by
Finishing m3/day
biological
Anaerobic
1,50,000 2400
E-10 Dyeing 3
2500 m /day 34 Crs Biological
Yards /day m3/day
(UASB)
Table 7.8: Types, Capacities and Treatment Technologies of the Studied Industries
Item Range
Production Capacity 4.5 Ton/day – 100000 MT/day
Industry Type Dyeing, Washing, Printing,
FinishingWashing only
Dyeing only
Dyeing and Washing
Knitting, Dyeing and RMG
Knitting, Dyeing, Washing, Finishing
Dyeing and RMG
Dyeing and Printing
Knitting, Dyeing and Finishing
Dyeing, Washing & Finishing
RMG Washing
ETP capacity 5 m3/day – 7500 m3/day
Investment cost for ETP 10 lacs – 34 cores (BDT)
Treatment Technology Physicochemical only
Biological (ASP) only
Physicochemical + Biological (ASP)
Anaerobic Biological (UASB)
Electro-chemical
Table 7.8 shows that the studied industries vary widely in production capacities, ETP
capacities and investment costs for the ETPs. It is worth mentioning that area allocated for
ETP also varies greatly from industry to industry. Some industries use huge area for ETP
units, especially for biological (ASP) treatment process. The industries which are located
within BSCIC area generally have space constraint. It is difficult to accommodate biological
treatment units in the available space and are fully dependent on chemical process, which
increases the treated effluent TDS as well as volume of sludge.
7.7 ASSESSMENT OF ZD STATUS OF ZLD-ETP INDUSTRIES
The DoE approved ZD plans under 3R policy were collected from DoE zonal offices. Ten
industries were selected for the study after comprehensive review of basic data (Section 3.2,
Chapter 3). During the field visit of those industries, an attempt was made to observe the 3R
measures adopted/implemented in the respective industry to achieve zero discharge. A
comparison was made between the proposed ZD measures and progress/achievement of the
ZD plans till June, 2017. Table 6.9 shows a summary of this comparison.
Table 7.9: Field Observation of Progress/Achievement of ZD/3R plan and the Proposed Measures
Industry ZD/3R plan Implementation till 2017

Code Approval Date Proposed ZD/3R units
1st year: primary treatment unit for 36% reuse (Scouring, bleaching, washing)  Primary treatment unit
Extra clarifier
2nd year: extra clarifier, sand filter, and AC filter for 25% reuse (Gardening, washroom, Sand filter
fire fighting) Activated carbon filter
Aug-23 RO unit
Z1 3rd year: sand filter, AC filter for medium and fine filtration for 30% reuse (washing unit Evaporation unit
& household purpose)
Provision of 180.5 m3 storage
4th year: RO unit for 8% reuse ( main dyeing process & final washing) tank of ETP treated recycle water
for fire fighting
5th year: Evaporation unit in RO system & 1% water is evaporated in air (salt recovery)
1st Phase- 20% (1st year) : 176 m3/day water reuse in Toilet flashing, chemical dosing  Multi-grade filter
tank, car & floor washing, fire fighting, road washing and others Activated carbon filter
Reservoir cum sedimentation
Treated water (reservoir cum sedimentation tank)→ MGF→ ACF →Reuse  Flocculation tank
Lamella clarifier
Z2 Aug-23 2st Phase- 80% (3st year) : 704 m3/day water reuse in Dyeing unit and bathrooms. Softener
Micro filter
Ro unit
Sedimentation tank→ Flocculation→ Lamella clarifier→ MGF → ACF→ Micron filter
→Softener → RO unit →Reuse
10-15 % water reuse in gardening
& car wash
1st and 2nd year (1st stage): reuse of effluent treated water RO unit
Z3 Aug-23 Incinerator unit
3rd year (2nd stage): RO unit & incinerator plant
No reuse
st
1 year: primary treatment unit for 36% reuse (Scouring, bleaching, washing)  Primary treatment unit
sep-23  Extra clarifier
Z4 2nd year: extra clarifier, sand filter, and AC filter for 25% reuse (Gardening, washroom, Sand filter
fire fighting) Activated carbon filter
3rd year: sand filter, AC filter for medium and fine filtration for 30% reuse (washing unit RO unit
& household purpose) Evaporation unit
4th year: RO unit for 8% reuse ( main dyeing process & final washing) 5 m3 reuse for gardening
5th year: Evaporation unit in RO system & 1% water is evaporated in air (salt recovery)
1st year: primary treatment unit installation for 36% reuse (Scouring, bleaching, washing)  Primary treatment unit
Sedimentation tank→ MG filter→ AC filter→ Softener → Micron filter→ Reuse  Sedimentation tank
Multi-grade filter
2nd year: Extra clarifier , Sand filter, Carbon filter for 55% water reuse in Reuse in Activated carbon filter
Dyeing & washing unit and gardening, washroom, fire fighting Softener
Micron filter
Z5 Oct-24 Extra clarifier
Sedimentation tank→ Flocculation→ Lamella clarifier→ MGF → ACF→ Micron filter
Sand filter
→Reuse
 Flocculation tank
Lamella clarifier
Evaporation unit
3rd year: medium and fine filtration in outlet and RO unit for 8% water reuse in dyeing
unit and rest 1% water in Evaporation unit to blow in air. No reuse
1st Phase- 20% (1st year) : 360 m3/day water reuse in Toilet flashing, chemical dosing  Primary treatment unit
tank, car & floor washing, fire fighting, road washing and others  Sedimentation tank
 Multi-grade filter
Treated water (reservoir cum sedimentation tank)→ MGF→ ACF →Reuse  AC filter
2st Phase- 80% (3st year) : 1440 m3/day water reuse in Dyeing unit and bathrooms. Lamella clarifier
Nov-24 Micron filter
Softener
Z6 Sedimentation tank→ Flocculation→ Lamella clarifier→ MGF → ACF→ Micron filter
RO unit
→Softener → RO unit →Reuse
Exhaust Gas Boiler (EGB), Boiler
with default Economizer, Rain
water harvesting,
Heat recovery in finishing, Hot
water Chiller, Servo motor M/C
in sewing machine, Heat Trap in
Ironing machine, LED light, Soft
start-up washing m/c
1st year: Hot Water Recovery, Automation System, Energy & Gas Savings, Wastewater  Automation System
Line Segregation and installation of Plumbing system, Dyeing cooling water recycle,  Water Flow meter Installation
Wastewater Recycle First Phase, Caustic Recovery Plant, Magneto Hydro Dynamics  Energy saving
Installation, Water Flow meter Installation  Plumbing system
Waste water recycle 1st phase
2nd year: Rain Water Harvesting, WTP new reserve tank for blackwash water storage, Caustic recovery
Magneto Hydro Dynamics
Bio Gas Plant, Sludge Disposal & Management
Rain water harvesting
Z7 Nov-15
New reserve tank for backwash
3rd year: Salt recovery Plant, Wastewater Recycle Second Phase, Sewage Treatment Biogas plant
Plant Salt recovery plant
STP
Waste water recovery 2nd
phase
No reuse
1st year: Water consumption reduction  Low Liquor ratio machine for
(60 gallon/kg), Minimization of water loss, Recycling of dyeing water water consumption reduction
 Minimization of water loss
2nd year: Rain water harvesting, Salt recovery Recycling of dyeing water
Z8 Dec- 17 3rd year: ETP expansion, Flow segregation, Ultra-filtration Salt recovery
ETP extension
Flow segregation
Ultra-filtration
No reuse
1st year: Hot Water Recovery  Hot water recovery from boiler
Z9 Dec-14  Condense recovery
2nd year: Rain water harvesting  Cooling water reuse
 Low liquor ratio in dyeing
3rd year: Energy Savings, Wastewater line segregation and installation sanitary work, machine
WTP new reserve tank for backwash water storage, Magneto hydro dynamic Installation  Servo motor for all sewing
machine
4th year: Waste water recycling 1st phase  EVC (Electronic Volume
Control meter)
 LED light for energy saving
5th year: Salt recovery plant installation, Waste water recycling 2nd phase (RO), STP
 Boiler within built Economizer
installation
RO unit
Salt recovery plant
STP
 Primary treatment unit
 RO unit
Treated and RO outlet water
tank of capacity 500 m3 for reuse
in washing M/C as per process
requirement
 Flash water tank of capacity
Data Not Available
125m3 for toilet flashing.
Z10  Final treated water tank of
dimension 0.98m x 0.75m x
0.88m
This industry reuses 35% of RO
treated water in the process and
recycles 43% of ETP treated
water in gardening, toilet flushing
etc. Therefore, overall reuse and
recycle achievement is 63%.
From Table 7.8, it is evident that although the ten industries were selected as ZLD-ETP
industries after reviewing their approved 3R plans, in reality, except for one industry (Z10),
none of the industries has ZLD units (such as RO, Evaporation unit, Salt Recovery Plant,
Micro Filter, etc.). Industry Z-10 has installed RO unit with ETP and it is the only industry
that is reusing the final treated water in its process. Therefore, the other nine industries should
not be treated as ZLD-ETP industries; they are ETP industries in reality.
Although most of the industries (90%) have not implemented the units/ components
mentioned in their 3R plans yet, many industries have adopted various measures to reduce the
discharge and emission and are recovering some heat energy and recycling some amount of
ETP treated water in different purposes. The most common features are recycling a certain
percentage (varies from 5% to 30%) of treated water for gardening, fire-fighting and toilet
flushing. Industry Z-6 has adopted many measures such as heat recovery in finishing, hot
water recovery from boiler and condensate recovery. It uses Low Liquor Machine in dyeing
which consumes less water. It has installed boiler with built equalizer for less gas use. It is
using cooling water in dyeing unit. There is newly installed Rain Water Harvesters (RWH) to
store rain water for use as process water. Some of their energy conservation measures include
LED lights, sewing machines requiring less energy, heat trap in ironing machine, soft-start
washing machines, etc. According to them, a small portion of treated water is used in
chemical mixing and use of low volume toilet flush and water tap also help save water. It
appears that this industry is very active in reduce, reuse and recovery processes. Industry Z-9
also adopted similar types of measures in reduce, reuse and recovery (Table 6.9). The total
reuse and recycle achievement of Z-10 is 63% because of employing RO with ETP. In
addition to that, industry Z-10 uses water and energy saving washing machines in washing
unit and water saving sanitary fixtures. It also recovers and reuses condensate. The
performance of Industry Z-3 and Z-5 is very poor in achieving 3R goals. Industry Z-8 has
received approval in January, 2017 and it has two and a half year remaining to implement the
proposed plan.
During the survey, it was observed that the industries without ZD plans are also practicing
reduce, reuse/recycle and recovery measures in running their industries. Table 6.10 shows
some 3R measures adopted in industries with only ETPs.
Table 7.10: 3R measures adopted in industries with ETPs only
Industry ID 3R Measures
E-1 • Systematic vegetation to increase water retention and recharge of
groundwater,
• plantation of red oak tree which releases highest O2
• white road surface to reduce radiation,
• cogeneration
• Use of hot steam chiller.
• Treated water recycles in flushing, gardening, road cleaning, aquaculture
etc.
Industry ID 3R Measures
• Provision of stone pits for vertical draining, resulting in increased aquifer
recharge.
• Composting plant using organic waste to make fertilizer.
• Liquid indigo is used instead of powder indigo to reduce toxicity and load on
ETP.
• Around 30 m3/hr water is saved in finishing unit and reused in WTP
• Recovery of condense from boiler and reused.
• LED lighting
• Total reuse and recycle is around 40% including 18% from ETP water
• Paper less policy to reduce the waste and thus conserving the resource.
• ETP sludge is recycled in brick making
E-2 • Hot water produced in boiler is recovered. This system was introduced in
January 2016
E-3 • Hot water produced in boiler is recovered.
E-4 • No mentionable 3R activities in practice
E-5 • Reuse of dyeing water in boiler.

• Use of Low liquor ratio machine reduces amount of water consumption.
E-6 • Hot water produced in boiler is recovered and this system was introduced
since 1993.
E-7 • Rain water harvesting RCC reservoir tank of 10,000L capacity was installed
in October 2016 which reduces water consumption.
E-8 • Solar panel of capacity 1200 Watt was introduced which reduces energy
consumption.
E-9 • No mentionable 3R activities currently.

E-10 • No mentionable 3R activities currently.
7.7 SLUDGE MANAGEMENT
Of all the industries surveyed, a few industries have filter press and sludge drying bed for
dewatering and reducing the volume of generated sludge at the ETP. Most of the industries
dry the sludge in open air naturally and then store it for days and finally dispose of the sludge
in landfills. It has been found from the study that two industries dispose of their sludge with
municipal solid wastes. One industry has conducted a research on sludge to investigate if
there are any hazardous elements in the sludge and are currently dumping in agricultural
filed. Another industry is using their sludge in brick making industry. Amount of sludge
generated at ETP is significant occupying large area. The amount of sludge generated in
UASB is considerably less than ASP and chemical treatment processes and sludge generated
in ASP is less than the chemical process. Therefore, the volume of sludge generation also
depends on the type of wastewater treatment technology adopted by the industries. Sludge
disposal is still a problem for the textile industries. The concept of ZLD is converting one
problem into another --- decreasing the volume of liquid waste but increasing the amount of
solid wastes. So, the paradigm of problem shifts from one form to another.
7.7 COST ANALYSIS
During the field visit, questionnaire survey was conducted (Annex A) to collect the
information on cost, water use etc. from the industry. Based on the collected information,
Table 6.11 presents the operational cost and capital investment in ETP.
Table 7.11: Capital Investment and Operational Cost of Selected ETPs
Industry Name ETP Operational Cost ETP Capital Cost (BDT)

(BDT/m3)
Z-1 12-14 10 Crs
Z-2 8 90 Lacks
Z-3 2 2 Crs
Z-4 10 4 Crs
Z-5 20 70-80 Lacks
Z-6 17 6 Crs
Z-7 Data not available 170 Crs
Z-8 12.5 6 Crs
Z-9 24 3 Crs
Z-10 48 Data not available
E-1 23-25 10 Crs
E-2 12-14 2 Crs
E-3 10 3 Crs
E-4 22 2.5 Crs
E-5 37 1.2 Crs
E-6 38 Data not available
E-7 6 40 Lacks
E-8 10 25-30 Lacks
E-9 5 2.5 Crs
E-10 75 34 Crs
The capital cost of ETP includes the cost of land, equipment, infrastructure construction etc.
and the operation cost of ETP includes cost of chemicals, energy bill, salary of ETP staff,
operation and maintenance etc. Table 6.11 shows that among the twenty industries, seven
industries operational cost of treatment for per unit m3 of wastewater is within Tk.2.00 –
10.00, five industries is within the range of Tk.11.00 – 20.00, five industries is within
Tk.21.00 – 40.00 and the rest three industries’ cost is higher than Tk. 40.00. It is observed
from Table 6.11, that the investment cost of ETP of all twenty industries varies in a wide
range depending on the technology, space and industry type but the variation in operational
cost of most of the industries is not much wide (Tk. 5.0–38.0 /m3 of water), except two
industries, Z-3 and E-10. Operational cost of Z-3 is 2.0 Tk./m3, which is very low and E-10 is
75.0 Tk./m3 which is very high compared to those of other industries. Industry E-10 has
implemented UASB technology and biofiltration in treating its wastewater in a huge area.
Therefore, its investment cost is very high compared to the other industries but the reason for
its high operational cost cannot be explained since in their UASB technology, it is not using
any chemicals, sludge recycling and mechanical aeration. There might be some mistakes in
providing the data for Z-3 industryw.r.t. operational cost.
7.9 TECHNOLOGICAL ASSESSMENT
Different types of technologies were observed in textile industry ETPs. Common

technologies include physicochemical (aeration, coagulation-flocculation, clarification and
filtration) and activated sludge process (biological). Of the surveyed industries, two industries
employs (Sequencing Batch Reactor) system which is aerobic biological process and one
industry employs anaerobic biological process (UASB). Industry E-9 has adopted Dissolved
Air Flotation (DAF) method in its physicochemical ETP system.
In industry Z-6, it is found that it has two flocculation tanks (one before SBR and
another after SBR,) two ozonation tanks (one before SBR and one after SBR), two sets of
inclined plate settler (one before SBR and one after SBR), Activate Carbon Filter and Multi-
grade Filter in the ETP. To study the effectiveness of these additional treatment units in this
ETP, one extra sample was collected at the outlet of SBR in excess of influent and final
effluent samples and was analyzed at BUET Laboratory. The test results are shown in Table
6.12.
Table 7.12: Test Results of Additional Sample at the SBR unit of Z-6
Outlet Removal Efficiency (%)

Parameters Inlet Before Recycle
(Final
(after SBR) After SBR At the outlet
disposal)
pH 10.54 7.75 7.6 -- ---
Color Pt-Co 484 287 284 41% 41%
Turbidity
66.6 11.9 11 82% 83%
(NTU)
DO (mg/L) 5.14 0.33 0.15 - 94% - 97%
BOD5 (mg/L) 187.5 24 26 87% 86%
COD (mg/L) 505 66 80 87% 84%
EC (µS/cm) 2660 4540 4550 -71% -71%
Cl- (mg/L) 205 290 295 -41% -44%
NH3-N (mg/L) 1.197 2.19 3.06 -83% -156%
3-
PO4 (mg/L) 0.299 0.738 0.81 -147% -171%
Outlet Removal Efficiency (%)
Parameters Inlet Before Recycle
(Final
(after SBR) After SBR At the outlet
disposal)
TDS (mg/L) 1848 3164 3173 -71% -72%
TSS (mg/L) 53 28 31 47% 42%
From Table 6.12, it has been found that the additional units in the ETPs are not so effective in
reducing the contaminants, instead the removal efficiency decreased for almost all
parameters.
Performance of the UASB type ETP (Industry E-10) was found to be very promising(Table
7.13), specially the color removal (efficiency 100%)and TDS (89%) compared to other
industries.
Table 7.13: Test Results of UASB system at E-10
Removal
Removal Removal Efficiency Overall
Parameters Inlet Before After Outlet Efficiency of Efficiency Removal
UASB UASB of
Neutralization of UASB Biofilter Efficiency
Tank (%) (%) (%) (%)
pH 11.52 6.90 6.99 7.48 40% --- --- ---
Color Pt-Co 8500 1300 620 10 85% 52% 98% 100%
Turbidity
(NTU) 744 60.9 24 1.2 92% 61% 95% 100%
DO (mg/L) 0.05 0.05 0.05 5.39 0% 0% 10680% 10680%

BOD5
mg/L 1160 550 230 0.40 53% 58% 100% 100%
COD
(mg/L) 2078 1234 498 5 41% 60% 99% 100%
EC
(µS/cm) 7370 2800 2690 264 62% 4% 90% 96%
Cl-
mg/L 520 540 500 80 -4% 7% 84% 85%
NH3-N
mg/L 14.46 19.60 33.125 0.224 -36% -69% 99% 98%
3-
PO
4
mg/L 2.35 15.65 40 0.445 -566% -156% 99% 81%
TDS
mg/L 1078 1734 1532 173 -61% 12% 89% 84%
Removal
Removal Removal Efficiency Overall
Parameters Inlet Before After Outlet Efficiency of Efficiency Removal
UASB UASB of
Neutralization of UASB Biofilter Efficiency
Tank (%) (%) (%) (%)
TSS
mg/L 396 90 49 11 77% 46% 78% 97%
It has been found from the study that the performance of UASB and Biofilter is very good,
especially in treating BOD5, COD and color (almost 100%) removal. Efficiency of Biofilter is
excellent in removing TDS and the overall removal of all parameters is very good.
The only industry which has RO system (Z-10) as a tertiary treatment. Samples were also
collected before and after RO unit to assess the performance of RO. Table 6.14 shows the
performance of RO system.
Table 7.14: Test Results of RO system installed at Z 10
Before RO (after Removal Removal Overall

Parameters Inlet Ion-exchange, Outlet efficiency of efficiency of RO Removal
coagulation- ETP (%) (%) efficiency
flocculation) (%)
pH 7.88 6.64 6.52 --- --- ---
Color Pt-Co 78 45 10 42% 78% 87%
Turbidity
(NTU) 85.1 15.7 0.72 82% 95% 99%
DO (mg/L) 5.59 3.09 3.67 -45% 19% 34%
BOD5
mg/L 100 11.2 0.4 89% 96% 100%
COD
(mg/L) 320 30 5 91% 83% 98%
EC
(µS/cm) 540 1369 367 -154% 73% 32%
Cl-
mg/L 165 315 187 -91% 37% -21%
NH3-N
mg/L 2.258 1.564 0.465 31% 70% 79%
3-
PO
4
mg/L 0.058 0.162 0.055 -179% 66% 5%
TDS
mg/L 341 855 200 -151% 78% 45%
TSS
mg/L 129 27 7 79% 74% 95%
Performance of conventional ETP units (coagulation-flocculation and ion-exchange) in this

industry is not good regarding color and TDS removal. Instead of reducing TDS, it has
increased TDS and the reason might be the use of PAC and Polymer in coagulation-
flocculation unit. It is known that RO is very effective in removing TDS and the test
results also support that. However, the industry is a washing industry and its influent
quality is not as poor as the dyeing industries. Again, the industry has introduced its
RO in August,2016 and as per their records it has not faced the problem of replacing
the membrane yet.
CHAPTER 8
8.1 INTRODUCTION
The present action research was undertaken with an objective to investigate the status of textile
industries in Bangladesh regarding their performance in effluent treatment and their progress in
achieving zero discharge under 3R plan. Keeping this objective in view, the research was
designed and conducted accordingly and the survey results and analysis were presented in
Chapter 5 and Chapter 6. This chapter presents a detail discussion on the survey findings and
results which may help to attain the goals and reach a conclusion. The discussion is focused in
the light of the objectives and outcomes of this research.
8.1 DISCUSSION ON PROPOSED TECHNOLOGICAL SCHEMES IN 3R

PLAN
The first objective of this research was to analyze approved 3R plans of different textile
industries to assess the technological schemes to achieve ZLD. It is worthy to note that the main
focus of this research is on Zero Liquid Discharge (ZLD), although the industries submitted their
3R plans in light of Zero Discharge (ZD). Introducing ZLD system (RO, Evaporation unit,
Crystallizer, etc. as Tertiary treatment system) with ETP usually is one of the main components
of achieving zero discharge. Therefore, the emphasis was given in the present study to assess the
technological scheme proposed by the industries. From the review of the plans, it was observed
that common technological schemes proposed by the industries are inclusion of Pressure Sand
filter, Activated Carbon filter, Multi-grade Filter, Micro filter, Ultrafilter etc. (Table 6.9). All
these units are meant to improve the treated water quality and increase the water reuse. The
industries have proposed to reuse this water in gardening, floor washing, toilet flushing,
firefighting purposes. All ten selected industries have proposed RO unit as ZLD component in
their treatment system to increase the water recycle percentage and to use this water in main
production process. Many industries have proposed evaporation unit with RO system to recover
the salt.
In the 3R plan, industries have suggested some other measures to reduce, recover and conserve
such as RWH, Energy Saving by LED lighting and sewing machine, heat recovery through
economizer, Bio-gas plant, incinerator, medical waste disposal process, etc.
8.1 DISCUSSION ON PROGRESS OF ZLD
The DoE started giving approval of ZD/3R plan in 2014. The industries have to implement
the plan phase by phase in 3 years ‘timeline. The present study was undertaken with a view to
find out how the industries have progressed with the implementation of their proposed plan to
achieve Zero Liquid Discharge. One of the objectives was to assess the consistency of the
proposed 3R plan with the actual scenario. It has been found during this research that
although the industries have proposed implementing ZLD units in their industry, very little
progress have been achieved so far. Of the ten selected industries as ZLD-ETPs, only one
industry was found to have RO system, the other nine industries have yet to start
implementing. Some industry time line has already expired and others are approaching the
end. There are many reasons behind this poor level of progress. It was learnt from the
industries that despite all the good intention they are unable to implement the proposed plans
because of many constraints. Some industries have huge space limitations, especially those
located in BSCIC Industrial area. Some industries have financial constraint, whereas, other
industries are struggling with the running of ETP smoothly. A few are investing in expanding
their production capacity, giving less priority on ZLD implementation. The research team
held dialogues with the ETP personnel and learnt that the industries have many queries and
confusions regarding the ZLD system. According to them, the ZLD technologies are highly
sophisticated, advanced system requiring skilled and experienced staff to run. There is a
serious dearth of skilled personnel. Capacity building through training and hands-on teaching
in this sector should be given priority. The effectiveness and sustainability of ZLD units
mostly depend on the efficient performance of ETP. Otherwise any advanced system such the
RO system will need frequent membrane replacement. Unfortunately, performance of the
ETPs of many industries is not even good enough to comply with the national standard, let
alone achieving100% zero liquid discharge. Another reason for not achieving much progress
in ZLD is that many industries have submitted the plans to get the clearance from DoE, but
they do not know how to proceed with the implementation process or are not yet ready to
implement those plans.
Although most of the industries visited (90%) by the research team have not implemented the
units / components mentioned in their 3R plans yet, many have adopted various measures to
reduce the liquid discharge and emission. Some industries are recovering some heat energy
and recycling some amount of ETP treated water for different purposes. The most common
features are recycling a certain percentage (varies from 5% to 30%) of treated water for
gardening, firefighting and toilet flushing. Industry Z-6 has adopted many measures such as
heat recovery in finishing, hot water recovery from boiler and condensate recovery. They use
Low Liquor Machine in dyeing which consumes less water, boiler with in-built equalizer for
less gas use. They are using cooling water in dyeing unit and stored rain water (through RWH
system) contributes to the process water. Some of their energy conservation measures include
the use of LED light, sewing machines which requires less energy, heat trap in ironing
machine, soft-start washing machine, etc. According to them, a small portion of treated water
is used in chemical mixing. Also, use of low volume toilet flush and water tap adds to their
water saving scheme. Thus, it is evident that this industry is very active in reduce, reuse
and
recovery. Industry Z-9 also adopts similar type of measures in reduce, reuse and recovery
(Table 6.9). In addition to RO system, industry Z-10 uses water and energy saving washing
machines in Washing unit and water saving sanitary fixtures in the toilets. It also recovers
condensate and reuses it. The total reuse and recycle of treated water of Z-10 is 63% because
of introducing RO (ZLD unit) with ETP. The performance of Industry Z-3 and Z-5 is very
poor in achieving 3R goals. Industry Z-8 has received approval in January 2017 and it has
one and a half year time to implement the proposed plan. Some industries have already
started using water saving machine/equipment in their processes to reduce the water
consumption at the source. Some industries are using those chemicals which are less toxic
and make less sludge. Therefore, these types of measures are certainly in line with 3R plans.
From this study, it was found that not only the industries which have received approval from
DoE but also the industries which are yet to submit plans have adopted many 3R measures.
One of the industries (E-1), which has not submitted 3R plan, is presently recycling around
40% of its treated water that is being used for many purposes. Other ETP industries are
practicing some forms of reduce and recycling measures (Table 6.10, Chapter 6).
Therefore, it can be said that if the ETP runs effectively, producing improved quality of
treated water, then a considerable amount of water can be recycled if the industry is willing.
Regarding the time frame mentioned in the proposed plan to achieve 3R goals, it is found that
almost none of the industries comply with the time line mentioned in introducing ZLD units.
There may be several reasons behind this: the industries are bit confused about how to
proceed with this, some industries have future plans in expanding their business and this may
require the extension/up gradation of their ETP which may take time, official complexities,
financial constraints etc. If there is any mechanism so that the industry could inform DoE
explaining the reason of not complying with 3R goals in proposed time frame, then DoE may
help them in resolving their issues.
8.1 DISCUSSION ON PERFORMANCE OF ZLD AND ETPs
Of the twenty industries selected for this study nineteen industries are running with ETP only
and one industry has ETP with ZLD (in the form of RO system). Therefore, comparison of
performance between these two unequal groups would be improper. Moreover, the industry
with RO system has only the Washing Plant whereas others are of various types. Therefore, it
would be appropriate to consider all the industries as one group while evaluating their
performance in treating the industrial effluent.
The baseline scenario of the influent to the ETP and treated effluent of the ETP of the studied
industries (20) are presented in Table 7.1 and Table 7.2.
Table 7.1: Wastewater Characteristics of Studied Textile Industries at Inlet
Industries Wastewater Quality Parameters

pH Color Turbidity DO BOD5 COD EC Cl- NH3-N PO43- TDS TSS
(Pt-Co) (NTU) (mg/L) (mg/L) (mg/L) (µs/cm) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L)
Z1 7.51 256 55.3 0.31 240 541 1772 180 0.942 1.38 1410 65
Z2 7.4 186 94.7 0.16 116 228 1240 390 1 0.325 669 94
Z3 9.83 1150 27.1 0.09 104 328 4520 150 2.21 0.95 3402 93
Z4 8.98 4000 49.7 2.73 160 816 13700 7400 5.94 0.147 10710 128
Z5 10.07 2340 361 0.19 720 3600 1264 135 5.32 0.298 1021 402
Z6 10.54 484 66.6 5.14 187.5 505 2660 205 1.19 0.299 1848 53
Z7 11.56 4500 249 0.81 700 1232 4410 380 11.63 4.74 3756 428
Z8 10.09 2650 746 1.0 140 561 2140 290 5.24 1.5 1418 128
Z9 9.74 3780 59.9 0.08 840 1728 7870 150 7.63 4.82 6226 350
Z10 7.88 78 85.1 5.59 100 320 540 165 2.26 0.058 341 129
E1 11.51 800 303 0.31 920 1856 3760 340 0.468 0.91 2736 242
E2 7.03 36600 371 5.64 240 687 755 240 1.46 0.16 678 586
E3 9.5 1700 88.2 0.11 112 372 3700 230 1.99 1.09 2804 240
E4 9.15 1420 219 0.1 256 704 4320 540 2.09 0.275 3302 226
E5 7.77 202 74.3 0 220 443 2710 140 0.54 1.04 2000 72
E6 7.72 1396 101 0.05 300 794 7120 350 2.03 0.392 5550 231
E7 7.68 1070 98.6 0.08 80 660 755 165 2.77 0.02 634 36
E8 5.63 53 51 4.25 28 137 863 125 1.23 0.038 601 93
E9 6.85 5500 56 5.21 128 698 6320 110 11.5 0.37 708 124
E10 11.52 8500 744 0.05 1160 2078 7370 520 14.46 2.35 1078 396
Range (min. – max.) 5.63 - 53 - 27.1 - 0- 28-1160 137- 540- 110- 0.468- 0.02- 341- 36-
11.56 8500 746 5.64 3600 13700 7400 14.46 4.82 10710 586
ECR, 1997 6.0-9.0 - - 4.5- ≤ 50 at ≤ 200 ≤ 1200 ≤ 600 ≤5 - ≤ ≤ 150
(Discharge into 8.0 200C 2100
surface water)
Table 7.1 shows that the concentration of all the parameters of the selected industries are very
high. It is evident that the wastewater of textile industries is heavily polluted with high
organic loading, less dissolved oxygen, and high dissolved solids which should not be
discharged directly into the environment without treatment.
The data shown in Table 7.2 indicates that the concentrations of the parameters of most of the
industries are within the allowable limit set by ECR, 97, except for DO and TDS. Therefore,
the treatment of textile industry effluent scenario is not so dismal. Considering individual
industries compliance status, it has been found that, 8 industries fail to comply with TDS,13
industries fail to comply with DO, 3 industries fail to comply with BOD5 and 4 industries fail
to comply with COD Standard (ECR, 97) (Figures 6.2, 6.3, 6.4, 6.5, 6.10, 6.11, 6.12 and
6.13).Therefore, it can be said that ETP of the studied industries is effective in reducing
BOD5 and COD but not so effective in reducing TDS and complying DO content. The color
removal efficiency of ETP is also not noticeable, although there is no standard for Color. Of
all the industries studied, the color removal of industry E-10 is very good (100%). The
technology adopted for treating its wastewater is UASB. From literature, it is known that
UASB technology is effective in removing color and the present study finding supports that.
Table 7.2: Treated Effluent Characteristics of Textile Industries at Outlet
Industries Treated Effluent Parameters

pH Color Turbidity DO BOD5 COD EC Cl- NH3-N PO43- TDS TSS
(Pt-Co) (NTU) (mg/L) (mg/L) (mg/L) (µs/cm) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L)
Z1 8.13 125 14.9 1.87 10 70 2280 180 0.338 0.08 1542 8.13
Z2 8.09 87 9.04 4.08 9.6 42 2460 510 1.69 0.492 1610 8.09
Z3 8.24 55 11.2 5.08 8 67 1841 455 0.55 0.105 1184 8.24
Z4 7.71 920 8.23 3.79 24 283 3590 405 1.05 2.435 2622 7.71
Z5 7.81 400 60.2 0.26 140 553 1148 365 1.5 0.095 840 7.81
Z6 7.6 284 11 0.15 26 80 4550 295 3.06 0.81 3173 7.6
Z7 7.32 1020 4.36 0.32 18 122 4360 90 1.712 3.2 3364 7.32
Z8 7.49 1150 5.58 4.23 5 57 3330 325 1.295 2.5 2289 7.49
Z9 6.9 310 25.5 5.39 32.5 95 5650 395 0.483 13.21 4137 6.9
Z10 6.52 10 0.72 3.67 0.4 5 367 200 0.465 0.055 187 6.52
E1 7.32 32 8.62 5.25 12.8 68 2160 680 0.469 0.505 1354 43
E2 6.99 110 14.3 0.25 56 159 1235 540 1.103 0.073 858 28
E3 7.72 148 8.62 5.39 8 44 1560 300 1.17 0.132 1107 35
E4 7.12 335 57.4 0.06 192 359 4090 470 0.457 0.082 3051 60
E5 7.4 113 33.2 0.05 40 119 2660 135 0.652 0.242 1790 45
E6 7.43 231 25.2 0.05 220 389 7000 600 2.9 0.256 5224 28
E7 7.3 85 4.07 0.38 10 67 1020 275 1.275 0.05 775 42
E8 7.64 13 1.29 6.07 1.2 7 1533 265 0.567 0.2 989 15
E9 7.47 820 23.9 5.24 7 53 3280 260 1.825 2.32 2298 27
E10 7.48 10 1.2 5.39 0.4 5 264 80 0.224 0.445 173 11
Range (min. – 6.52- 10- 0.72- 0.05- 0.4-220 5-553 264- 80-680 0.224- 0.05- 173- 7-72
max.) 8.24 1150 60.2 6.07 7000 3.06 13.21 5224
ECR, 1997 6.0- - - 4.5-8.0 ≤ 50 at ≤ 200 ≤ 1200 ≤ 600 ≤5 - ≤ ≤ 150
(Discharge into 9.0 200C 2100
surface water)
8.1 DISCUSSION ON TECHNOLOGIES
Various technologies have been found in twenty studied industries such as chemical process
(coagulation-flocculation), Activated sludge process and Up-flow anaerobic sludge blanket
process (UASB). Most common are coagulation and ASP. Few industries were found to use
return sludge in their biological treatment process (ASP). Most of the industries have only
clarifier/settling tank with long detention time along with chemical treatment (coagulation-
flocculation) units which facilitates in decomposing organic load and thus removed by
biological process. Due to the wide variation of technologies, it will very difficult and
unrealistic to recommend from this study that one technology is better compared to other or
generalized for treating the wastewater effectively. The reason is that every industry is
different in terms of its type, production capacity, wastewater flow rate, raw materials and
chemicals use in the process etc. However, some observations were made from the findings
of this study and based on these observations, comments can be made which may guide in
selecting the right technology. It has found that in some industries, many units are included
and the test results show that inclusion of these units are not reducing the contaminants,
rather contributing to the pollution load (Section 6.9, Table 6.12). These units seem
unnecessary in ETPs and increase the investment cost and operational cost to ETP. However
more tests should be done for establishing this fact. Again, it is evident from test results of
many industries, that although the use of PAC, Poly-electrolyte, Polymer, and decoloring
agent remove COD and color, it increases TDS, exceeding the allowable limit. This high
TDS can only be removed by using RO system to achieve ZLD and the effectiveness of RO
also depends on the quality of treated effluent, otherwise the membrane will haveto be
replaced frequently increasing the operational cost.
It is worthy to mention here that many ETPs are performing well and practicing 3R measures
(reduce, recycle, recovery) (up to 40%) in their industries. Therefore, if the industry can run
their ETP effectively, they can recycle a considerable amount of water without increasing the
cost. The ZLD concept is to convert the liquid into solid phase. Unfortunately, this only
transfers the problem from liquid phase to solid phase.
8.1 ASSESSMENT OF ZLD AND ETPs IN TERMS OF COST
The study team found it very difficult to get the information on cost involved in ETPs (both
capital cost and operational cost) from the industries. Most of the industries could not provide
these data since they do not have this in record. Whatever data collected from some of the
industries seem to be unrealistic and unreliable. However, an attempt was made to determine
the operational cost of ETPs (Section 6.8, Chapter 6). It is observed from the Table 6.10, that
the investment cost of ETP of all twenty industries varies in a wide range depending on the
technology, space and facility but the variation in operational cost of most of the industries is
not much different (5.0 – 38.0 Taka/m3 of water), except for two industries, Z-3 and E-10.
Industry E-10 has implemented UASB technology and biofiltration in treating its wastewater
in a huge area. Therefore, its investment cost is very high compared to the other industries but
the reason for its high operational cost is not known since, it is not using any chemicals,
sludge recycling and mechanical aeration in UASB technology. There might be some
mistakes in providing the data of operational cost from other industry.
It has been found from the study that the land area and treatment technology (includes
equipment) dominates capital cost. In addition, lack of skilled manpower in handling of ETP
is a major factor influencing operational and maintenance cost. And as industry tends to use
more advanced and sophisticated technologies like RO, MEE, Crystallizers, the need of
skilled man power in this area will be increasing.
To achieve ZLD, the industry is in need of financial support and technological support from
the Government and capacity building should be given priority in this sector.
8.1 DISCUSSION ON HANDLING MECHANISM OF

REJECT/CONCENRATE OF ZLD SYSTEM
One of the objectives of this research was to identify the handling mechanism of
reject/concentrate of wastewater from ZLD units. Since only one industry in the present study
has ZLD (RO) system and they have installed this unit in last year August. Therefore, they
have not faced any problem with the disposal of reject/concentrate yet. Again, if there are
more industries with RO system in operation, it is quite possible that those are also recent.
However, the disposal of this reject will be a concern if more industries are going to install
this to obtain the treated water quality as potable water and 100% reuse them in process
water.
Regarding the sludge management of ETPs, it has been observed that, few industries have
filter press, sludge digester and sludge drying bed for dewatering and decreasing the volume
of generated sludge at the ETP. Most of the industries dry the sludge in open air naturally and
then store it for days and finally dispose of the sludge in landfills. It has been found from the
study that two industries dispose of their sludge with municipal solid wastes. One industry
has conducted a research on sludge to investigate the presence of hazardous elements;
subsequently is using in agricultural filed. Another industry is using their sludge in brick
manufacturing. Amount of sludge generated at ETP is significant occupying large space. The
amount of sludge generated in UASB is considerably less than ASP and chemical treatment
processes. On the other hand, sludge generated in ASP is less than that in chemical process.
Therefore, it is evident that volume of sludge generation also depends on the type of adopted
treatment technology. Sludge disposal is still a major problem for the textile industries. The
introduction of ZLD units in treatment processes will generate more sludge and disposal of
this sludge will be another concern for the industries.
8.1 DISCUSSION ON OPERATION AND MAINENANCE OF ETP
During this study, discussions were held with industries regarding the operation and
maintenance related problems in running ETPs. A few of these problems mentioned by the
industry personnel are listed below:
• High operational cost;

• Insufficient lab facility and shortage of skilled manpower;
• Consumes huge amount of chemicals in physicochemical process;
• High volume of sludge generation in physicochemical process;
• Limited sludge disposal options;
• Lack of landfilling sites for sludge disposal;
• Reduction of TDS in treated effluent is extremely difficult and involves tertiary
treatment increasing the cost of operation.
8.1 EVALUATION OF REDUCTION IN GROUNDWATER

EXTRACTION
Another objective of this research was to evaluate the overall drop of groundwater extraction
in respective industries due to implementation of 3R plan. The research team found it very
difficult to estimate the reduction in water use. The primary problem is that many industries
don’t have the data on how much water they use especially in their industrial process. They
do not have any water meter installed. In those industries where part of treated water is
recycled/reused, there is no record or meter, measuring the recycled/reused amount. Another
significant reason is that the industries are expanding on a regular basis, resulting in more
water consumption. Therefore, even if these industries recycle a part of treated effluent, the
total demand remains much more than the reused/recycled amount. Thus, the burden on
groundwater extraction is increasing instead of decreasing. Therefore, the study team strongly
suggests that metering system is introduced in the water supply line at the inlet and the final
outlet. Monitoring of the flow data will help to determine the amount of water used, reused
and recycled and thus, will enable one to estimate the level of reduction of groundwater
extraction.
CHAPTER 9
Conclusions
9.1 CONCLUSIONS
The major conclusions drawn from this research are as follows:

• The study findings show that the overall scenario of wastewater treatment of textile
industries in Bangladesh is fairly good. The randomly selected all the twenty industries
have ETPs and the concentration of all tested parameters of most of the industries’
treated effluent are within the allowable limit of ECR,97 except DO and TDS.
• Of the twenty industries treated effluent concentration, seven industries comply with
the minimum DO requirements and thirteen industries fail to comply; considering
BOD5 concentration, seventeen industries comply and three industries fail; sixteen
industries meet the allowable limit of COD and four industries fail to meet; regarding
TDS, twelve industries comply with the ECR, 97 standards and eight industries fail to
comply.
• Nine out of ten selected industries that have approved zero discharge plans, have not
implemented ZLD units yet as proposed.
• Although most of the industries do not have ZLD units with their ETPs according to
their proposed plan, six industries out of ten such industries, are practicing many 3R
measures (reduce, reuse, recovery) at their facility. The common measures are use of
water and energy saving machines in the process, use of less toxic chemicals, boiler
with built-in economizer, reuse of water in gardening, toilet flushing, fire fighting,
condense recovery, heat recovery in finishing, LED lighting, RWH, water saving
sanitary fixtures etc. (Table 6.9).
• The industries without zero discharge plans also have 3R measures in place. Seven
industries out of ten are practicing measures such as hot water recovery from boiler,
reuse of boiler water in dyeing, use of solar panel, RWH, LED lighting, Low liquor
ratio machine etc. (Table 6.10).
• For the lone ZLD-ETP (RO system with ETP) industry in this research, the total reuse
and recycling of treated water is found around 63%.
• The amount of recycled water is found in the range of 5% to 40% considering the
industries (nineteen) with conventional (physicochemical and biological processes)
ETP only. The percentage of this reuse is achieved only by applying different measures.
It is observed in this study that the industry’s good intention is the main driving force
of attaining zero discharge.
• The operational cost of ETP varies in the range of Tk. 5.0- 38.0 per m3 of wastewater
treated. No correlation is found between the operational cost of ETP and the production
capacity and the technology/processes being used in the treatment process.
1
• The study observed that attitude of the industry is a major factor in reducing the
pollution created by the industry. If the industry feels the responsibility of protecting
the environment along with its economic contribution, and act accordingly, only then
they will be successful in achieving zero discharge.
9.2 RECOMMENDATIONS
Based on the research findings and discussion, following recommendations are made.
• DoE should introduce use of flow meter at the inlet and outlet of every industry. Only
by doing this, the amount of reused/recycled treated water can be determined and
monitored.
• As ZLD technology is very expensive, there should be some incentive from government
in form of subsidy or soft loan for the industry to implement the technology and reduce
the pollution.
• If the ETP treated wastewater of the industries can be collected and then treated in a
centralized ZLD system, the cost will be less and industries will be able to secure their
business as well as the environment
• Before implementing ZLD technology, every industry should ensure that their ETP is
performing effectively, otherwise ZLD will not work properly.
• The industries which are in shortage of land (specially in BSCIC area) for
accommodating biological and ZLD units, alternative arrangements should be made
from the government to treat their wastewater i.e. arrangement for CETP.
• The success of achieving zero discharge also depends on source reduction. Use of less
toxic chemicals and advanced machineries in the process reduce the water
consumption. Financial support should be given to the industry to promote this,
especially for small scale industries.
• There is a dearth of skilled man power in handling, operating and maintaining the
advanced technology and sophisticated machines in ETP and ZLD units. Capacity
building in this area is strongly recommended.
• There should be some mechanisms/arrangement between DoE and industry so that the
industry could inform DoE explaining the reason of not complying with 3R goals in
proposed time frame, then DoE may help them in resolving their issues.
The research team believes that if the abovementioned recommendations can be implemented,
both the industry and DoE will be benefited and pollution created by textile industries can be
managed sustainably and the pollution scenario of the country will improve significantly.
2
9.3 CONSTRAINTS AND LIMITATIONS
The research team has faced many constraints and challenges while conducting the work. These
are as follows:
• The samples were collected from the industry only once. It would be more
representative if more samples could be collected from the same industry since
industrial wastewater composition varies widely with time.
• Most of the industries could not provide reliable data on ETP cost, water consumption,
amount of recycle water etc., therefore the cost-benefit analysis regarding technology;
water reuse could not be performed.
• If these industries were of the same type and have same ETP processes, then suggestion
could be made on specific amount of water reuse potential for a given technology.
However, the studied industries are of various types (dyeing, washing, composite etc.)
and sizes (capacity), and therefore suggestion made like this would not be realistic and
logical.
• Unfortunately, the research team found only one industry among the 10 selected
industries (as ZLD-ETP) which has RO system, although the 10 industries supposed to
have RO system according to their approved plan. Therefore, the team has not found
enough data and information of ZLD units and consequently the conclusions are mainly
made based on ETP system, not ZLD-ETP system.
9.10 Advantage Of ZLD
Zero Liquid Discharge (ZLD) in water treatment processes offers several significant advantages,
both from environmental and economic perspectives. Here are key advantages of implementing
ZLD:
Environmental Sustainability:
➢ Minimized Environmental Impact: ZLD significantly reduces the discharge of liquid

waste into water bodies, preventing pollution and protecting aquatic ecosystems. It helps
in meeting stringent environmental regulations and promotes sustainable water
management.
Resource Conservation:
➢ Maximized Water Recovery: ZLD focuses on recovering and reusing as much water as
possible from the treatment process, minimizing the overall demand on freshwater
sources. This is crucial in regions facing water scarcity or where water resources are
limited.
Compliance with Regulations:
➢ Regulatory Adherence: ZLD ensures compliance with environmental regulations by

eliminating or drastically reducing the discharge of pollutants. This helps industries and
municipalities avoid fines, legal consequences, and reputational damage associated with
3
non-compliance.
Economic Benefits:
➢ Resource Efficiency: ZLD promotes efficient use of resources such as water, chemicals,
and energy. By optimizing processes and minimizing waste, industries can achieve cost
savings and improve the overall economic viability of their operations.
Reduced Disposal Costs:
➢ Elimination of Disposal Costs: ZLD eliminates the need for costly disposal methods for
liquid waste. Instead of treating and discharging wastewater, industries can recover
valuable resources and reduce the expenses associated with waste disposal.
Energy Recovery:
➢ Potential for Energy Generation: ZLD processes often include technologies that allow for
the recovery of energy from wastewater. This can include the capture of biogas or the
utilization of thermal energy, contributing to the overall sustainability of the facility.
Enhanced Public Perception:
➢ Corporate Social Responsibility: Implementing ZLD demonstrates a commitment to

environmental stewardship and corporate social responsibility. This can enhance the
public perception of businesses, attracting environmentally conscious consumers and
investors.
Risk Mitigation:
➢ Reduced Risk of Contamination: By eliminating liquid discharge, ZLD reduces the risk
of accidental releases and contamination incidents. This is particularly important for
industries dealing with hazardous substances.
Long-term Water Security:
➢ Safeguarding Water Resources: ZLD contributes to long-term water security by

promoting responsible water usage and minimizing the environmental impact of
industrial processes. This is crucial for ensuring a sustainable water supply for future
generations.
4
Future Work
1. Enhancement of Treatment Efficiency:
To improve the overall efficiency of the zero liquid discharge (ZLD) system, future research
could explore advanced treatment technologies. Investigate the integration of emerging
membrane technologies, such as forward osmosis or electrochemical processes, to enhance the
removal of contaminants and increase the recovery of valuable resources.
2. Integration of Renewable Energy Sources:

Evaluate the feasibility of incorporating renewable energy sources into the ZLD system. Assess
the potential use of solar or wind energy to power the treatment processes, aiming for a more
sustainable and environmentally friendly operation. This could involve techno-economic
analyses to determine the cost-effectiveness of such integration.
3. Optimization of ZLD System Design:

Conduct comprehensive optimization studies to fine-tune the design parameters of the ZLD
system. Explore the optimal combination of pre-treatment methods, crystallization techniques,
and brine management strategies. Utilize advanced modeling and simulation tools to identify the
most energy-efficient and cost-effective configurations.
4. Long-Term Performance Monitoring:

Establish a long-term monitoring program to assess the performance and reliability of the ZLD
system over extended periods. Investigate potential changes in the quality of treated water,
membrane fouling rates, and the durability of system components. This longitudinal study can
provide valuable insights into the system's robustness and identify areas for continuous
improvement.
5. Life Cycle Assessment (LCA):

Conduct a comprehensive life cycle assessment to evaluate the environmental impact of the ZLD
system. Consider factors such as embodied energy, carbon footprint, and resource depletion.
This assessment can aid in identifying opportunities for minimizing the environmental footprint
of the ZLD process and guide decision-making toward more sustainable practices.
6. Exploration of Novel Materials:

Investigate the use of novel materials for membranes and other key components of the ZLD
system. Research on advanced materials with enhanced selectivity, durability, and resistance to
fouling could contribute to the development of more robust and efficient ZLD technologies.
7. Scale-Up and Pilot Studies:

Scale up the ZLD system for real-world industrial applications and conduct pilot studies to
validate its performance under different operating conditions. Collaboration with industry
partners can facilitate the implementation of the technology on a larger scale and provide
insights into practical challenges that may arise during full-scale deployment.
5
8. Regulatory Compliance and Policy Advocacy:
Collaborate with regulatory bodies and policymakers to advocate for the adoption of ZLD
technologies. Investigate the regulatory landscape, identify potential barriers, and work towards
creating a supportive framework for the widespread implementation of ZLD systems across
industries.
9. Public Awareness and Education:

Develop educational programs and outreach initiatives to raise awareness about the benefits of
ZLD systems. Foster understanding among stakeholders, including industry professionals,
policymakers, and the general public, to promote the adoption of sustainable water management
practices.
6
REFERENCES
Ashraf A (2015), ‘Zero Liquid Discharge: A success story of Tirupur Textile Cluster’, The Apparel
Story, p. 41-43, Oct-Nov 2015.
btmadhaka.com, 'Dyeing-Printing-Finishing', found in BTMA website:

http://www.btmadhaka.com/Dyeing-Finishing-Printing, retrieved on February 2, 2017.
Center for Environmental Education (CEE), (2016), ‘The Concept Note for Challenges against
Implementation of ZLD in Textile Processing Industries and Clusters in India’, Industrial Pollution
Prevention Group, CEE, Ahmedabad, April 2016.
DoE (2016), Department of Environment, ‘ECC Meeting Minutes', found in DoE Website:
http://www.doe.gov.bd/site/page/e13e1ea0-53c2-4251-aa9b-
d5d850b8411d/%E0%A6%87%E0%A6%B8%E0%A6%BF%E0%A6%B8%E0%A6%BF-
%E0%A6%AE%E0%A6%BF%E0%A6%A8%E0%A6%BF%E0%A6%9F%E0%A6%B8,
retrieved on February 2, 2017.
DFID (n.d), 'Promoting Zero Liquid Discharge Mandate for Bangladesh Textile Industry', Policy
Paper Series prepared by Institute for Industrial Productivity, KPI and IPE Global, funded by
UKAID, viewed through
http://www.ipekpp.com/admin/upload_files/Report_1_19_Promoting_1175846345.pdf retrieved on
5 March, 2017.
Hussain, I.S. (January, 2014), “Indian Case Study on ZLD- The Tirupur Textile Cluster
Experience”.
Islam, M.M., Mahmud, K., Faruk, O., Billah, M.S. (2011), “Textile Dyeing Industries in Bangladesh
for Sustainable Development”, International Journal of Environmental Science and Development,
Vol. 2, No. 6.
Sagris T. and Abott J. (2015), ‘An Analysis of Industrial Water Use in Bangladesh with a focus on
the textile and leather industries’, 2030 Water Resources Group (WRG).
Tillberg, F. (2004), “ZLD-Systems, An Overview”, Department of Energy Technology, Royal

Institute of Technology, KTH, Stockholm.
7
REFERENCES
1. Munter, R., Industrial Wastewater Treatment: Pathways Of Industrial Effluents
Treatment. 2012. p. 195-210.
2. Pescod, M.B., Wastewater Treatment And Use In Agriculture. 1992, Food And
Agriculture Organization Of The United Nations: Rome. p. 37-56.
3. Eddy, M.a., Wastewater Engineering Treatment and Reuse. Vol. 2nd Ed. 2003:
McGraw - Hill, New York.
4. Singh, J., Effluent Treatment Plant: Design, Operation And Analysis Of Waste Water
2012: p. 14-23.
5. Joe Bostjancic, R.L., Getting to Zero Discharge: How Recycle That Last Bit of Really
Bad Wastewater. 2013, GE’s Water & Process Technologies.
6. Series, P.P., Promoting Zero Liquid Discharge Mandate for the Bangladesh Textile
Industry. 2015, Government of UK’s Department for International Development. p. 1-
8.
7. Mohammad A. Hoque, M.M.H., Kazi Matin Ahmed, Declining groundwater level

and aquifer dewatering in Dhaka metropolitan area, Bangladesh: causes and
quantification. Hydrogeology Journal, 2007. 15(8): p. 1523-1534.
8. Management Information Report for the month of November 2003. Monthly Bulletin.
2003, WASA (Water Supply and Sewerage Authority): DWASA, Dhaka, Bangladesh.
9. Maswood, M., Groundwater levels in Dhaka falling rapidly, in The New Age. 2015:
Dhaka, Bangladesh.
10. M. Akhtaruzzaman, A.C., Jerry Knapp, Mahbubul A. Mahmood, Samiya Ahmed,

Choosing an Effluent Treatment Plant. 2012, Bangladesh Centre for Advanced
Studies: Dhaka, Bangladesh.
11. The Environment Conservation Rules 1997, (unofficial translation), D. Ministry of

Environment and Forests, Editor. 2000, Government of the People’s Republic of
Bangladesh: Dhaka, Bangladesh.
12. ZERO LIQUID DISCHARGE (ZLD) SYSTEM. 2016; Available from:
http://www.degremont-technologies.com/~degremon/ZERO-LIQUID-DISCHARGE-
ZLD-SYSTEM.
13. Tillberg, F., ZLD-systems An Overview. 2004, Department of Energy Technology,

Royal Institute of Technology, KTH: Stockholm. p. 1-15.
14. Mickley, M., Survey of High-Recovery and Zero Liquid Discharge Technologies for
Water Utilities. 2008, WateReuse Foundation: Alexandria, VA
15. Evaluation and Selection of Available Processes for a Zero-Liquid Discharge System
for the Perris, California, Ground Water Basin, in Desalination and Water
8
9

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PLC Based water Treatment Plant With Zero Liquid

Department of Electrical & Electronic Engineering

Md. Ranu Sarker

Orun Badsha Rubel

Md. Kamrul Islam

1. Ms. Anika Fariha Rashid

Ms. Tahia Tasnim Islam

2. Mr. Sharif Uddin

3. Mr. K.M Daiyan

TABLE OF CONTENTS .....................................................................................….iii

LIST OF FIGURES AND TABLES.......................................................................... v

1.1 Zero Liquid Discharge ................................................................................................. 2

2 Effluent Treatment Methods ................................................................................................ 4

2.1 Physical Unit Operations [4] ....................................................................................... 4

2.1.1 Screening ....................................................................................................... 4

2.1.2 Flow Equalization ......................................................................................... 5

2.1.3 Sedimentation and Filtration ......................................................................... 6

2.1.4 Aeration ......................................................................................................... 6

2.2 Chemical Unit Processes [4] ........................................................................................ 7

2.2.1 pH Control ..................................................................................................... 7

2.2.2 Chemical Coagulation and Flocculation ....................................................... 8

2.3 Biological Unit Processes [4] ....................................................................................... 8

2.3.1 Activated Sludge ........................................................................................... 9

2.3.2 Fixed Film ..................................................................................................... 9

2.4 Physio-chemical Treatment........................................................................................ 10

2.5 Physio-chemical and Biological Treatment ............................................................... 10

3 Programmable Logic Controller………………………………………………………..11

3.3 Historical Background of PLC………………………………………………………12

3.4 Basic PLC Architecture …………………………………………………………….12

3.4.3 Programing Device……………………………………………………………14

3.4.4 Input & Output Section……………………………………………………......14

3.5 The Guts inside of PLC……………………………………………………………..14

3.6 Working Function of Each Part of PLC……………………………………….…...15

3.7 PLC Operation……………………………………………………………………..15

3.8 Features and Advantaged Of PLC………………………………………………….16

3.9 Disadvantaged Of PLC……………………………………………………………..17

3.10 Difference Between ………………………………………………………………..17

3.11 Requirement Component Of ZLD for PLC……………………………………….18

3.11.2 Operation of Relay

3.11.3 Type of Relay

3.11.4 Application of Relay

3.11.5 Solenoid Valve

3.11.6 Operation of Solenoid Valve

3.12 Arduino Add Base Scanda For water plant………………………………………….21

3.12.2 Hardware Component ……………………………………………………….21

3.12.3 Summary …………………………………………………………………….22

3.12.4 Problem Statement …………………………………………………………..25

3.12.5 Theoretical Framework………………………………………………………..26

3.12.6 Practical Farmwork…………………………………………………………...34

4 Introduction of ZLD in Bangladesh ............................................................................... 46

4.1 Reasons to Introduction of ZLD in Bangladesh ...................................................... 46

4.1.1 Ground Water Level ............................................................................................... 47

4.1.2 National Standards for Wastewater ........................................................................ 49

4.12.4 Benefits of ZLD .......................................................................................... 49

4.12.5 Challenges of ZLD...................................................................................... 49

5 Overview on Zero Liquid discharge .............................................................................. 50

5.1 Process Selection ..................................................................................................... 51

5.2 Some ZLD Process Examples: .................................................................................. 54

5.2.1 Ionics’ EnChem. A ZLD-solution for the semiconductor industry ............................ 55

5.2.2 Tenergys’ plating waste water recovery system ......................................................... 55