Water Reuse 4/04/13
PURPOSE PROCESS PAYOFF
Water Water Everywhere but not a drop to drink!
Seawater versus Water Reuse UF - RO for brackish waste water streams: 0.81.2 kw h/m3 MBR RO for brackish waste water streams: 1.2 1.5 kw h/m3. Seawater: 2.3-4.0 kw h/m3. Recovering and reusing wastewater is dramatically less expensive then producing seawater and should be considered in conjunction with developing a seawater source treatment facility
Typical Water Uses -- Food & Beverage Plant Boiler & Clean Steam Feedwater Cooling Tower Makeup Other Food Rinsing Bottle Washing Can Rinsing Truck Washing Crop Irrigation Tea Production Main Plant Feed Reclaimed Water Wastewater Treatment CIP Make Up Product Water Purification
Conservation Opportunities Incoming plant water treatment high recovery, low waste In-plant processes End of pipe wastewater Treatment And recovery Bottle Rinse water Recovery Chemical Recovery Line Rinsing sugar concentration Cooling Tower Blowdown recovery
Incoming Plant Water Treatment system Well or surface Water supply Primary Reverse Osmosis System Product water SD I<1 Concentrate Microfiltration Softening or Ultrafiltration pretreatment Large volumes of incoming plant water can be wasted if the recovery of a reverse osmosis system is limited because of its initial design (typically maximum 75% recovery) or because of inadequate pretreatment. Product water Concentrate to wastewater system Brine Reverse Osmosis System Processing Applications Culligan can review and optimize existing installations through the enhancement of pretreatment technologies such as Ultrafiltration or Microfiltration Membrane Softening. Recovery can also be enhanced through the addition of a Brine Recovery Reverse Osmosis System. Water utilization efficiencies can be increased from 75% up to 90% to 95%.
In Plant Processes Bottle Rinse Water Recovery In-plant processes Reverse Osmosis system to remove dissolved solids Bottle Rinse water Recovery Chemical Recovery Line Rinsing sugar concentration 90% of Rinse water can be recovered making the rinsing process virtually a closed loop Final Rinse Rinse water from a bottling line is typically of better quality then the incoming water supply and efforts to recover it should be made. Ultrafiltration System for solids removal and enhancement of RO system recovery.
In Plant Processes Chemical Recovery In-plant processes Bottle Rinse water Recovery Chemical Recovery Line Rinsing sugar concentration Recovered Caustic Spent acids or caustics can be recovered through membrane technology Spent Caustic Nanofiltration System
In Plant Processes Line Rinsing Sugar Recovery In-plant processes Bottle Rinse water Recovery Chemical Recovery Line Rinsing sugar concentration Recovered water can be reused for rinse water or boiler feed. Specialty Reverse Osmosis or Nanofiltration system to concentrate up the dilute sugars to produce a concentrated product that can be used for animal feed. When changing flavors during the bottling phase lines are rinsed producing diluted sugar streams
RO Brine and Cooling Tower Recovery 5% concentrate to pond or evaporator Process water RO concentrate SD I<1 Cooling Tower Blowdown Reverse Osmosis Microfiltration Softening OVERALL SYSTEM RECOVERY 95% Water reuse back to cooling towers
End of Pipe Wastewater Treatment System Wastewater Product From Production Processes water Ultrafiltration System Existing Biological Treatment Plant Reuse water for [production applications reduce size/cost and volume of water required for process water system Reverse Osmosis System Concentrate
Uranium Mine Effluent Treatment example Pretreatment Trailer Open pit mine drainage Backwash To sludge thickener Notes: Resin can be once through option and disposed with Radium and Uranium contained Potential for regen plant to be built, reclaim about 40,000 lbs of product Two Stage IX system for Radium and Uranium removal Concentrate To process water pond Option 1 IX and RO Blended stream Discharged to wetlands RO permeate from existing system
Textile Wastewater Solution Self clean inline screen Incoming Waste Water.6 MM drum screen 1/3 hp 30,000 gallon tank 1000 gallon Cone bottom Screen solids Screen solids Solids return to close looped production process or disposed of Ultrafiltration system Recyled water back to wash process typically less then 1 TSS Solids return and concentrated
ZLD FOR TIRE MANUFACTURE Well Water supply Primary Reverse Osmosis System Product water SDI <1 Microfiltration Softening Concentrate Concentrate to wastewater system Product water Brine Reverse Osmosis System Bridgestone Firestone Mexico Tire Process manufacturing Applications Water OVERALL SYSTEM RECOVERY 95%
ZLD FOR TIRE MANUFACTURE 5% concentrate to pond Process water RO concentrate SDI <1 Cooling Tower Blowdown Reverse Osmosis Production Microfiltration Softening Water reuse back to cooling towers Bridgestone Firestone Mexico - Wastewater OVERALL SYSTEM RECOVERY 95%
ZLD FOR TIRE MANUFACTURE Facility Type: Tire production plant Process: Pretreatment Membrane Softening for Reverse Osmosis systems Wastewater Treatment Goals: Increase Reverse Osmosis system recovery Reduce wastewater Improve system reliability Reduce operating costs (membrane replacement, cleaning manpower) Preserve limited water supply membrane
Rolls Royce Indiana
Rolls Royce Indiana Ultrafiltration system Wastewater storage tank have skimmer to remove tramp and free oils that will foul UF Hydrocyclone remove solids Duplex hypochlorite injection pumps concentrate storage tank pump end of batch then add polymer and precipitate solids and break oil emulsions to reduce hauling Batch tank Concentrate to be hauled approx 10 to 20% of original NF Feed. Permeate for reuse approx 80 to 90% of NF feed. permeate Nanofiltration system
Reuse Design Considerations Start with the water quality desired and select the technology required to produce that water quality. Work backwards from that technology and the design process becomes an exercise in pretreatment optimization. Why? Increase reliability and productivity, and reduce operating cost and down time. What will you do with the residual concentrated waste streams? What are the discharge limits? Can you discharge the Concentrates economically? Far too often basic reuse systems are designed without consideration of long-term reliability and operating cost!
Reuse Design Considerations Example Wastewater Greenfield facility Metals manufacturing plant can be vehicle, appliance furniture. Manufacturing operations. Machining Cleaning Painting Plating Typical waste streams. Organics from metal cutting fluids (BOD/COD) Metals 300 ppm Acid and caustics (TDS) 3,000 ppm Organics from paint (BOD/COD). 500ppm BOD 800 ppm COD Flow 200 gpm.
Reuse Design Considerations Typical waste streams. Organics from metal cutting fluids (BOD/COD) Metals 300 ppm Acid and caustics (TDS) 3,000 ppm Organics from paint (BOD/COD). 500ppm BOD 800 ppm COD Desired results TDS less then 100ppm BOD less then 1ppm COD less then 50 ppm Zero metals. Zero oil and grease.
Reuse Design Considerations Available technologies for TDS reduction Evaporation Capital cost and operating cost to high at 200 gpm. Ion Exchange Capital cost and operating cost at 3000 ppm. Reverse Osmosis Most reasonable technology for TDS removal.
Reuse Design Considerations Pretreatment For Reverse Osmosis BOD/COD Removal Oil and grease TSS Metals SELECT BIOLOGICAL TECHNOLOGY TO REDUCE BOD/COD and SOLUBLE OIL AND GREASE.
Reuse Design Considerations Biological Treatment Activated sludge Fixed film Biological treatment reduces BOD/COD but creates residual solids that require removal. Solids must be removed prior to RO. Clarifier followed by UF Membrane Biological Reactor MBR Biological treatment system will reduce BOD to less then 10ppm or 1 if MBR selected. COD reduction typically is in the range of 20 to 50 ppm. This is typically suitable for
Reuse Design Considerations Biological treatment system will reduce BOD to less then 10ppm or 1 if MBR selected. COD reduction typically is in the range of 20 to 50 ppm. This is typically suitable for discharge. RO will increase COD in concentrate up to 4 to 5 Times. Biological treatment will produce water suitable for discharge RO will raise the concentration. Is it economically feasible to reuse water? RO concentrates must be considered. COD and TDS meet discharge criteria. TDS meets it but COD does not. Oxidation of COD. TDS and COD both over limit. Further Concentrate treatment. Evaporator?
Reuse Design Considerations Pretreatment Biological Treatment Oil and grease Metals SELECT METALS PRECIPITATION TECHNOLOGY TO ELIMINATE METALS AND O&G.
FINAL SOLUTION RESIDUAL SOLIDS METALS PRECIPITATION WATER FOR REUSE BIOLOGICAL TREATMENT REVERSE OSMOSIS CLARIFIER ULTRAFILTRATION CONCENTRATE TREATMENT
QUESTIONS QUESTIONS?