Application of water pinch technology for water and wastewater minimization in aluminum anodizing industries

Transcription

1 Int. J. Environ. Sci. Tec., 7 (2, , Spring 200 ISSN: IRSEN, CEERS, IAU S. M. Kezri et al. Application of water pinc tecnology for water and wastewater minimization in aluminum anodizing industries *S. M. Kezri; F. Lotfi; 2 S. Tabibian; Z. Erfani Department of Environmental Engineering, Graduate Scool of te Environmental and Energy, Science and Researc Branc, Islamic Azad University, Teran, Iran 2 Faculty of Agriculture, Roodeen Branc, Payame Noor University, Teran, Iran Received 20 October 2009; revised 26 November 2009; accepted 8 February 200; avaiable online Marc 200 ABSTRACT:Tis study aims to describe te application of water pinc tecnology in industrial water consumption management in aluminum anodizing industry. Water pinc analysis is a systematic tecnique for designing, optimization and retrofitting of energy, mass and water recovery networks. Te selection of different operations existing in an industry as an important role in correctness of application of pinc tecnology. Water usages in anodizing industry are various, but researces ave been sown tat, it as te best efficiency on te selection of rinsing cambers to pinc tecnology. Tere are different metods in pinc tecnology mostly based on mass transfer of single or multiple contaminants. In tis researc, a new metod is used to select effective contaminant to be applied to pinc analysis. Tis researc is based on Mann and Liu s metod in single contaminant. But te guide for classification of raw water, wastewater and recycled water for industrial and recreation is cosen to use a complex of index contaminants as a single contaminant. Tis metod is very simple and applicable for various industrial processes. By an index contaminant like total dissolved solids, te water usage reduced about 6.7 %. Using pinc tecnology and tis new approac in tree rinsing cambers, water usage reduced about 4.4 %. Keywords: Aluminum anodizing; Industrial water reuse; Mass transfer networks; Process integration, Water consumption minimization INTRODUCTION Today, lack of water for bot drinking and industries purposes in te environment is a global concern. Terefore, it is igly important to protect of water sources. Tere are so many researces in water minimization to solve tis problem in industries wit different spatial approaces (Sorin et al., 999; Scneider et al., 2000; Jezowski, 2008; Yu-Der et al., Process canges for minimizing of process water demand (Kutepov et al., 2002; Soon et al., 2002; Tokozani, 2005; Manan et al., 2006, reuse of wastewater of a process in anoter process (Wang and Smit 994; Song et al., 2006; Vander Bruggen and Braeken., 2006; Wan Alwi and Manan, 2008;Abbaspour et al., 2009; Igbinosa and Oko, 2009 and recycle of process wastewater to te same process (Dole et al., 996; Castro et al., 999; Hallale et al., 2002; Alva Argaezea et al., 2007; Carlos et al., 2007; Zaolin et al., *Corresponding Autor kezri_m@yaoo.com Tel./Fax: are some approaces. Tese are some metods in wastewater minimization. Te pinc tecnology recently used is an efficient metod for wastewater minimization, because tree type of minimizing processes are included in one metod (Panjesai et al., 2008; Saobo et al., 2008; Soaib et al., Conceptually, water pinc tecnology is a same metod for mass excange integration involving water using operations (Alva-Argaez et al., 999; Mubarak Ebram et al., 2000; Juliana et al., 2007; Kai Cao et al., However, tis metod does not involve some practical problems tat inder te real world implementation of mass excange network, simply because water pinc tecnology represents an existing class of manufacturing operation. Water pinc analysis is a process integration tool, wic was first developed for te design of eat recovery systems during te late 970s (Linnoff, 970. Wang and Smit (994 considered tis tecnique for water using networks.

2 S. M. Kezri et al. Teir approac was based on mass transfer. Dole et al. (996 introduced an approac sligtly different to tat of Wang and Smit (994. Tis metod was deigned to overcome te problem encountered in real life application of te Wang and Smit metodology. El-Halwagi and Manousioutakis (989; El-Halwagi et al. (2000; Rabie and El-Halwagi (2008 introduced te concept of syntesizing waste-inception networks and incorporated tem into a mass integration framework for global allocation of pollutants. Gomes et al. (2007 presented an algoritmic procedure based on te construction of a concentration. Manan HWDO(2006 described ow te water cascade analysis tecnique was adapted to establis te minimum water target for te Sultan Ismail Mosque in Malaysia. In tis researc, a new metod is applied for determining index contaminant tat sows te complexity of contaminant as a single contaminant. Tus, calculation results will be more correct tan single contaminant. Also, Mann and Liu s metod in single contaminant (Mann and Liu, 999 is igly applicable. Tis metod is a grapical metod and uses simple matematical calculation, but it is applicable for various industries. Tis researc conducted in at Alopan Company in Alborz Industrial Estate Gazvin, Iran. MATERIAL AND METHODS Alupan Company as been establised in 974 in Alborz Industrial Estate in Gazvin for production of profile and door/window, facades wit annual production capacity of,000 MT in 50,000 m 2 wit a production all of 25,000 m 2. As sown in Fig., aluminum anodizing process consisted of fifty operations, wic seven of tem are rinsing processes and tree operations include continues processes (numbers 4,,. Oter processes supplied byalborz industrial area water ave weekly discarge. In wastewater minimization wit pinc tecnology tere are two purposes: Wastewater minimization wit considering single contaminant; Wastewater minimization wit considering multiple contaminants. Because of operational and tecnical limitations and lack of a compreensive approac about multiple problems and acceptable results wit reasonable little time consumption, wastewater minimization wit considering te single contaminant is a primal goal trougout tis study. In single contaminant problem, a contaminant wit most effectiveness in process sall be selected. Unfortunately, tere is no special information about contaminants level of required water in rinsing process in aluminum anodizing. In tis study, te guide for classification of raw water, wastewater and recycled water for industrial and recreation is used like a required standard to water usage in rinsing operations in aluminum anodizing industries. In tis guide, industrial water is classified in four classes: First class (ig sensitive Second class (sensitive Tird class (relatively sensitive Fort class (less sensitive Rinsing water is classified in less sensitive group. Waters in tis group are usually used witout treatment or wit minimum treatment. Te maximum level of eac parameter in Table is te closest level to allowable level for process in class four. National Sanitation Foundation (NSF are te pattern and numbering of tese carts. Tables 2 and indicates te numbering for eac group. Tis researc is based Cleaning Ecing Ecing Rinsing 4 Rinsing 5 Neutralization 6 Rinsing 2 Rinsing Painting 0 Rinsing 9 Rinsing 8 Anodizing 7 Rinsing Sealing 4 Sealing 4 Fig. : Alupan aluminum anodizing flowcart 282

3 Int. J. Environ. Sci. S. Tec., M. Kezri 7 (2, et , al. Spring 200 on Mann and Liu s (999 metod in single contaminant on grapical approac. In grapical metod, concentration composite curve, blok diagram and grid diagram were used. Applied metod was able to present water reuse, water regeneration and water recycle and also it was able to be used in multiple contaminant water minimization system. But in te current study, it as only been used for single contaminant wit a new approac using combination of contaminants as a pollution index instead of one contaminant. RESULTS AND DISCUSSION After sampling from all rinsing processes, all parameters in Table were measured wit Spectropotometer DR Hatc 2800 apparatus according to Standard Metods. Te results ave been sown in Table 4. Table 5 sows te numerical limitation of various groupe of water for rinsing operations. However, in tis case continues operations are considered, so oters operations are to be omitted and te results of tree operations are sown (numbers 4, and (Table 6. Determination of numerical limitation In determination of acceptable quality of water for rinsing operations, te following points are to be considered: Outlets of tese operations are te sampling points, because all rinsing operations use te same source of raw water, and ten te quality of waters are same. From te standpoint of numerical limitation (Table 5, te quality of water in inlet of operations is considered to be from group A (Table 2. Actually te numerical limitation (Table 2 is te water purity. Terefore, te level of waters contamination are determined from te following simple equation: Table :Te allowable level of parameters in class four of industrial water Parameter Te allowable level Fe 0- Mn 0- ph COD 0-75 Hardness Alkalinity SO Suspended Solid Cl 0-50 Si 5-0 TDS 0-00 Source: Te guide for classification of raw water, wastewater and recycled water for industrial and recreation Te level of water contamination is equal to 00 minus Numerical limitation. Determination of conditions Basic conditions for eac operation are: C Lim Concentration of contaminant in inlet streams ( i,in. Concentration of contaminant in outlet streams(c Lim. i,out Mass load of contaminant to be transferred ( mi,tot. All te above-mentioned conditions are sown in Table 7. Minimum flow rate of fres water witout reuse Firstly, minimum fres water flow rate needed for eac operation is determined. f = i,min gr m i,tot w w [ C i,out C i,in ] ( w In tis researc, ( C concentration of water in inlet i,out of operations is equal to 27 g/m gr f = = m 4, min [60 27] g Table 2: Numerical limitation of various groupe of water sources Numerical limitation Water source quality Very good Good (A 50-0 Moderate (B 0-0 Bad (C Source: Te guide for classification of raw water, wastewater and recycled water for industrial and recreation Table : Weigt of various parameters of industrial water Weigt Parameter 0.5 ph 0.5 Mn 0.5 Fe Cl SO Suspended solids COD Si 2 Hardness Dissolve solids Alkalinity 28

4 Application of water pinc tecnology S. M. Kezri for et water al. and wastewater minimization Table 4: Te results of measuring of various parameter of rinsing operations Unit Water SO 4 ph mg/l Mn mg/l Fe mg/l Cl mg/l Suspended solids mg/l COD mg/l _ Si mg/l Hardness mg/l Dissolved solids mg/l Turbidity mg/l Table 5: Numerical limitation of various rinsing operations water Rinsing operations Water quality f (l/s 4 B B 8 A 9 B B B B 0.95 Raw water A Table 6: Summary of calculations of operations 4, and Caracter Amount of testing Value (Q Weigt of parameter Q W 2- SO ph Fe Mn COD TSS Cl Si TDS Hardness Number of operation SO 4 = Numerical limitation ph Fe Mn COD TSS Cl Si TDS Hardness SO 4 = ph Fe Mn COD TSS Cl Si TDS Hardness

5 Int. J. Environ. Sci. Tec., S. M. 7 Kezri (2, , et al. Spring 200 Table 7: Limiting process data Process f (m / Inlet NSF Outlet NSF Inlet concentration Outlet concentration m Cumulative (g/m (g/m (00-NSF (g/m (00-NSF (g/m (g/ Mass load(g/ Table 8: Minimum fres water flow rate Operation Minimum fres water Outlet concentration flow rate (m / (g/m follows: Slope = 50 f ( mi n Overall tis Fig. tere is an inverse relationsip between te slope of te water supply line and water flow rate as Te point tat tis line touces te concentration gr composite curve is te pinc point (Wang and Smit, a. Te pinc point for tese operations is in te f ( m,min = = 2.6 [ 60 ] 27 g concentration of 50 gr. Te advantage of m determining of tis point is tat, te operations above it do not need for freswater and te operations below 68.4 gr m tat need freswater. f = =, min g [ ] Concentration interval diagram Te concentration intervals are applied again like Table 8 sows te results above. te concentration composite curve (Table 9. In tis Terefore, tere are minimum fres water flow rate Table, te mass load transferred in eac concentration equal to 6.02 m /. Tis is less tan total required flow interval is to be calculated. It can be seen tat, pinc rate, 7.28 m /, ence it is acceptable. point is in interval equal to 50 gr m. For calculation te mass load transferred in eac concentration Minimum flow rate of fres water wit reuse interval, following simple equation is applicable: Ten, after establisment of te freswater requirements for te system witout water reuse, process integration is to be carried out. Wastewater * * [ C ] g Lim m m ( k = k + C k f i from one operation can be reused directly in anoter m i operation provided tat level of contamination from 40 m [.42 = [ 0 ] ] operation A does not interfere wit operation B (i.e., te inlet concentration for te water stream remains 6 g m = below ( C Lim. Reusing te water streams in tis way B,in reduces bot freswater and wastewater volumes, but 50 m 2 [.42 = [ 40 ] ] leaves te mass load of contaminant transferred 7.28 g m = uncanged. In process integration, te concentration composite curve or concentration interval diagram m 2 = [60 50 ] (CID are applied (Mann and Liu, 999. [ ] 7.08 g m = Concentration composite curve Fig. sows te concentration composite curve for four operations in Alupan industry. In tis curve, te x axis is te mass load and te y-axis is concentration. In m Te flow rate can be calculated from te following equation: (2 285

6 S. M. Kezri et al. m k f m = k g C * k 0 f m = = 0 m 0 6 f m.5 m = = 40 g 4.28 f m = 50 = 2.6m g f m 2.9 = = m 60 g (4 Water using network design For designing preliminary water using network, Mann and Liu s concentration interval metod is igly appropriate. Grid diagram Briefly, a gird diagram consists of concentration interval boundaries, process streams, water streams and water using units and teir mass loads of contaminant: Firstly, orizontal dased lines are depicted wic sow te concentration interval boundaries. To te left of te diagram, arrows pointing downward (solid lines are drawn between te inlet and te outlet concentrations of te contaminant to represent eac process stream representing te water using operation. 7.6 In eac interval, te mass load of contaminant to be transferred for eac process stream is calculated. Table 9: Concentration interval diagram Concentration Operation Operation Operation 4 Cumulative Mass m(g/ (g/m.42(m / 2.88(m/ 0.828(m / Load(g/ Flow rate (m / Concentration (g/m Concentration Composite curve Pinc point Water supply line F min = Mass load (g/ Fig. 2: Concentration composite curve 286

7 Int. J. Environ. Sci. S. Tec., M. Kezri 7 (2, , et al. Spring 200 * * C k + C k mi,k (g / = mi,tot ( g / Lim Lim C i,out C i,in 40 0 m, ( g / = 68.4( g / = m, ( g / = 68.4( g / 50 0 = m, (g / = 84.4(g / = 28.4 ( m, 2 ( g / = 84.4(g / 60 0 = m, ( g / = 84.4( g / = m4,2 ( g / = 6.56( g / = m 4, ( g / = 6.56( g / = 28.4 f m, (m / = = 2.6( [40 27] Te second dased bold arrow, transfer 2.6 ( freswater to operation in interval. m Interval 2: In tis interval, tere are tree water using operations. Water sources are selected in te following order: First, water is reused from te same process in te previous interval; second, water is to be reused from oter process and finally, freswater is acieved. Firstly, water needed for operation is calculated in second. Tis operation can use te outlet water from operation in interval. Terefore, 2.4 f m,2 (m / = =.42( [50 40] g For eac operation, in a selected concentration interval, te water flow rate is calculated corresponding to te mass load of te contaminant for operation i in interval k, f tot : i, k f (m / = i, k tot mi, k (6 [ C C ] * w k+ i,k m In tis equation,c w is te average contaminant i, k concentration of te water stream for operation i entering interval k. Interval : In tis interval, it is necessary to use fres water: 2.4 f m, (m / = = 2.6( g [40 27] Wit drawing te dased bold arrow, te fres water needed for operation in interval is sown. Tis operation needs ( m freswater to transfer g mass load of 28.4(. For operation 4 in interval 2, it sall use freswater f m 4,2 (m / = = 0.6( [50 27] g Interval : In tis interval, tere are two operations ( and 4. According to te following equation, operation needs 2.84 m / water for transferring 28.4g/m mass load of contaminant f m, (m / = = 2.84( g [60 50] Te outlet of operation in interval 2 is 2.65 m /, ten, 0.2m / water is transferred from operation in interval 2, to tis operation = 0.99 H ~

8 0.6 m / m / = m / Application of water pinc Sorption tecnology beavior S. M. Kezri for of nine water et al. Cr(III and wastewater minimization Te next operation is operation 4. Te required water of wastewater is very important. In te oter and, waste for tis operation is calculated wit te same manner minimization troug pinc tecnology, is an effective introduced above. metod to reac tis goal. In tis researc, wit applying te pinc tecnology 8.28 in tree rinsing operations, te flow rate reduced up to f 4, (m / = = 0.828( m.026 m / (from 7.28 m / to 6.02 m /. Te metod [ ] of tis researc is based on single contaminant; owever, a complexity of efficient contaminant is used as a standard Te outlet of operation 4 in interval 2 is less tan to be secure to use of outlet of one operation to anoter. tis amount. Tus, m / water is transferred from It is better to use multiple contaminant to ave operation in interval 2 to tis operation. good results. Te matematical optimization and using of computer programming ave exact results. Fig. 4 sow Grid diagram and Block diagram for tree rinsing operations, respectively in Alupan. CONCLUSION Today, te lack of freswater, damage of discarging wastewater in te environment, costs of freswater supplying and wastewater treatment, ave forced researcer to develop various metods to decreasing freswater usage, especially in ig consumption industry. Water consumptions in anodizing is ig and because of ig contamination of outlet of anodizing wastewater to te environment and surface and groundwater, producing an applicable metod to reduce water consumptions of anodizing and terefore, refusing B 4.2 g/ Op.24 m / Op Op m / m / Nomenclature Q: Te value of a parameter according to standard. W: Te weigt of a parameter according to standard. C Lim i,in : Te limiting contaminant level in inlet of operation. C Lim : Te limiting contaminant level in outlet of i,out operation. : Te mass load of transferred contaminant. mi,tot w C i,in : Concentration of water in inlet of operation. f : Minimum flow rate in inlet of operation. min mi,k : Te mass load of transferred contaminant in eac interval k for operation i. f i,k : Te required flow rate for transferring contaminant in eac interval k for operation i. C * k + : Contaminant concentration in upper interval boundary. Wastewater 6.02 m / 55 g/m C* = m / m / 50g/m m / G m / 60 g/m 60 g/m 8.28 g/ E 2.84 m / 28.4 g/ D 28.4 g/ C 28.4 g/ F 8.28 g/ C* =50 C* 2 =40 A 4.2 g/ 2.6 m / 27 g/ 2.6 m / 27 g/ C* =0 Freswater 6.02 m / Fig. : Gird diagram 27 g/m 288

9 Int. J. Environ. Sci. Tec., S. M. 7 Kezri (2, , et al. Spring 200 Wastewater 6.02 m / 55 g/m 2.44 m / 2.85 m / m / 50 g/m 60 g/m 60 g/m 0.2 m / Op E Op G 4.27 m /.27 m / 40 g/m Op B m / m / Op D 0.6 m / m / 40 g/m Op F 4 Op A Op C 2.6 m / 27 g/m 2.6 m / 0.6 m / Freswater 6.02 m / 27 g/m Fig. 4: Block diagram ACKNOWLEDGMENTS Te autors grateful toalopan Company as well as Ms. Soleimani for teir cooperation in tis researc. REFERENCES Abbaspour, M.; Mirbageri, S. A.; Monavvari, M.; Javid, A. H.; Zarei, H., (2009. Conceptual ydrosalinity model for prediction of salt load from wastewater flows into soil and groundwater. Int. J. Environ. Sci. Tec., 6 (, (0 pages. Alva- Argaeza, A.; Vallianatos, A.; Kokossis, A., (999. A multi- contaminant transsipment model for mass excange networks and wastewater minimization problems. Comput. Cem. Eng., 2 (0, (5 pages. Alva-Argaez, A.; Kokossis, A. C.; Robin, S., (2007. Te design of water using systems in petroleum refining using a water pinc decomposition. Cem. Eng. J., 28 (, -46 (4 pages. Carlos, E.; Mariano, R.; Victor, H., (2007. Multi-objective optimization of water-using systems. Eur. J. Oper. Res., 8 (, (7 pages. Castro, P.; Matos, H.; Fernandes, M. C., (999. Improvements for mass excange networks design. Cem. Eng. Sci., 54 (, (7 pages. Dole, V. R.; Ramcandani, N., (996. Make your process water pay for itself. Cem. Eng., 0 (, 00-0 (4 pages. El-Halwagi, M. M.; Manousioutakis, V., (989. Syntesis of mass excange networkers. AICEJ, 5 (8, ( pages. El-Halwagi, M. M.; Gabriel, F.; Harell, D., (2000. Rigorous grapical targeting for resource conservation via material recycle / reuse networks. Ind. Eng. Cem. Resour., 42 (9, (0 pages. Gomes, J. F. S.; Eduardo, M. Q; Fenando, L. P., (2007. Design procedure for water / wastewater minimization: Single contaminant. J. Clea. Produc., 5 (5, (2 pages. Hallale, N., (2002. A new grapical targeting metod for water minimization. Adv. Environ. Res., 6 (, (4 pages. Igbinosa, E. O.; Oko, A. I., (2009. Impact of discarge wastewater effluents on te pysico-cemical qualities of a receiving watersed in a typical rural community. Int. J. Environ. Sci. Tec., 6 (2, (8 pages. Jezowski, J., (2008. Review and analysis off approaces for designing optimum industrial water networks. Cem. Process Eng., 29, (9 pages. Juliana, F. S.; Eduardo, M. Q.; Fernando, L. P. P., (2007. Design procedure for water/wastewater minimization: Single contaminant. J. Clea. Product., 5 (5, (2 pages. Kutepove, A. M.; Mesalkin, V. P.; Nevskii, A. V., (2002. Modified water pinc metod for desining resource efficient cemical engineering systems. Doklady Cem., 8 ( (5 pages. Kai, C.; Xiao F.; Hang M., (2007. Pinc multi agent genetic algoritm for optimizing water using networks. Comput. Cem. Eng., (2, ( pages. Linnof, B.; Hindmars, E., (970. Te pic designing metod for eat excanger networks. Cem. Eng. Sci., 8 (5, (9 pages. Manan, Z. A.; Wan Alwi, S. R.; Vjanag. Z., (2006. Water pinc analysis for an urbun system: A case study on te sultan Islmail Mosque at te Univercity Tecnology 289

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