ZERO LIQUID DISCHARGE The Ultimate Challenge Fluor. All rights reserved. FLUOR is a registered service mark of Fluor Corporation.

Transcription

1 ZERO LIQUID DISCHARGE The Ultimate Challenge 2015 Fluor. All rights reserved. FLUOR is a registered service mark of Fluor Corporation. 1

2 Agenda Introduction Drive towards ZLD Block Flow Diagram Fluor s approach to ZLD Design requirements Specific Processing/Operational Challenges Sludge/Salt Disposal Summary Questions 2

3 Fluor- what do we do? Client with an idea and a business plan Operating facility producing the right product in a cost competitive and sustainable way

4 Fluor- what do we do? Client with an idea and a business plan Fluor Turning ideas into reality Operating facility producing the right product in a cost competitive and sustainable way a passion to build!

5 Drive Towards Zero Liquid Discharge Integrated Pollution Prevention and Control - IPPC Recovery and Reuse of Water Environment Protection Implementation of Best Available Technologies Local Authorities rules on discharge limits High cost of liquid discharge & disposal 5

6 CONVENTIONAL WWTP WITH ZLD WASTE WATER FROM DIFFERENT UNITS CRYSTALLIZATION EVAPORATION MEMBRANE PRE FILTRATION TREATMENT PERMEATE SLUDGE HANDLING CORRUGATED PLATE INTERFACE REVERSE CONDENSER OSMOSIS PERMEATE PRE HEATERBUFFER TANKS STAGE I DEAERATOR RECYCLE WATER TO WWTP REVERSE OSMOSIS CRYSTALLIZER FLOCULATION EVAPORATOR PERMEATE STAGE II FLOATATION SALT CAKE UNIT REVERSE CLARIFIER OSMOSIS TO CRYSTALLIZER CENTRIFUGE EVAPORATOR PRE STAGE III DISPOSAL HEATER HEATER & HEATER SUBMERGED ULTRAFILTRATION BIOTREATOR DISCHARGE TO SEA TO SLUDGE HANDLING SYSTEM ZERO LIQUID DISCHARGE

7 Design Requirement by Client Design a system suitable for variable inlet stream Equalization & Buffer capacity Easy Cleaning, Operation & Maintenance Redundancy & Multiple trains Prevent build up of hard COD (Chemical Oxygen Demand) Treatment of bleed stream Fenton process, Ozone treatment Minimize waste volume(brine,salt,sludge ) Disposal /Logistics Waste streams to meet HSE requirements Sludge stabilization Optimization on CAPEX & OPEX 7

8 Approach to ZLD Typically an independent add on to a conventional WWTP with technology provider Input / Co-Operation Addition of third stage Reverse Osmosis Evaporator Preheater Deaerator Crystallizer Centrifuge etc 8

9 Fluor's added consideration for ZLD Evaluation of streams if they can be processed differently Within Normal WWTP Directly to ZLD unit Detailed early discussion with vendors Utilization of Fluor s global expertise Proven Knowledge Online system Plant capacity vs logistics Buffer tanks / Evaporation ponds Fit for purpose design Waste Water Treatment is an art Expert judgment required 9

10 Specific processing challenges Oxidized Spent Caustic Contributes to the 2/3 of the total design salt load Waste Water from Process Units Flow & Composition Cooling Tower Blow down/side Stream Filter backwash Phosphate &TSS (Total Suspended Solids) Regeneration waste - Demineralization/Condensate Polishing Unit TDS (Total Dissolved Solids)/ Ammonia/Phosphate UF/RO cleaning waste High COD load Contaminated rain water/fire water Flow/Oil & Grease/TSS Waste generation 10

11 Waste Generation Quantity Type Typical Quantity from a petrochemical complex Daily Yearly Salt (tons) 30 to 40 ~13,000 Bio-sludge from ETP (m3) Sun dried Bio-sludge (tons) ~ 40 ~15,000 ~7 ~2,500 11

12 Specific Operational Challenges Biological sludge disposal (Contains~80% water) Logistics High flushing frequency for ZLD equipments High OPEX Exotic metallurgy required for ZLD equipments High CAPEX Salt Disposal Requires large space, limited application for the salt produced Treatment of run off water required at landfill area Challenge Opportunity 12

13 Opportunities for further Improvement Enhancement of Evaporation process Reduction in salt load to ZLD by applying bio treatment instead of caustic treatment Smaller capacity ZLD Lower CAPEX 13

14 Opportunities for further Improvement Absorption Section Flash Vessel SULPHUR Reaction Section Sulphur Recovery Section 14

15 Sludge/Salt Disposal Sludge Disposal Large space requirement Sludge stabilization/sterilization Logistics Alternative - Incineration Salt Disposal Large space requirement High movement of trucks Limited application for the salts generated (ex Glass, Cement Industry) 15

16 Summary ZLD unit is simply not an add ON, it is much more complex Fit for Purpose Design- Optimization on CAPEX and OPEX 16

17 Level of Influence Project Expenditures Influencing Project Costs Major Influence Overall Influence Curve Rapidly Decreasing Influence Project Authorization Project Expenditures Low Influence Front-End Loading Mechanical Completion Conceptual Phase Feasibility Phase Front-End Eng.&Design Project Life Cycle EPC Construction TO/SU HA

18 Summary ZLD unit is simply not an add ON, it is much more complex Fit for Purpose Design- Optimization on CAPEX and OPEX Early expertise involvement leads to Fit for Purpose design Utilization and Brainstorming of global expertise within Fluor, from partners and vendors helps to identify modifications early ON 18

19 Question Time 19