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Industrial wastewater reuse_Anil Sharma_2013

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The global water challenges, reuse of industrial wastewater and ZeeWeed MBR technology information.

The global water challenges, reuse of industrial wastewater and ZeeWeed MBR technology information.

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  • 1. Industrial Wastewater Reuse December 13, 2013 Anil Sharma, P.Eng Regional Leader – Process, APAC
  • 2. Presentation Outline • General • ZeeWeed MBR Technology • Industrial Wastewater Reuse Case Studies • Automotive • Refinery/Petrochemical • Food & Beverages • Conclusions • Q&A
  • 3. Global water challenges Availability • Deteriorating water quality • Increased industrial pollution Quality Environmental Energy • Growing population and industry • Climate change and draught • Stricter regulation on discharge/withdrawal • Water reuse incentives and mandates • Energy to increase ~30% by 2030 • Demand for water to increase ~40% Growing water scarcity and impairment
  • 4. Types of Reuse Urban Reuse • Irrigation of parks, highway medians, golf courses, etc. • Commercial uses such as vehicle washing, window washing, etc. • Fire protection • Dust control and concrete production • Toilet and urinal flushing • Construction water Groundwater recharge • Aquifer reinjection • Subsurface infiltration • Surface infiltration Industrial Reuse • Cooling water • Boiler make-up water • Industrial process water Agricultural reuse Environmental and recreational • To create, restore, and/or enhance wetlands • Recreational and aesthetic impoundments eg. Ornamental ponds Reclaimed wastewater is an increasingly important source of supply 4
  • 5. GE Water’s UF/MBR Membrane Technology Applications Core Membrane Technology Drinking Water • Municipal Water • Marine & Defence • Consumer (Retail) Sewage • Municipal Sewage • Water Reuse • Land Development • Marine & Defence Industrial UF Pretreatment Make-up water for: • Boiler feed • Cooling towers • Process water Industrial WasteWater • Membrane Bioreactor • Tertiary filtration • Water reuse
  • 6. ZeeWeed Technology
  • 7. MBR (Membrane Bio Reactor) & Tertiary Treatment ZeeWeed® MBR Simplified Treatment Process Wastewater ZeeWeed® Tertiary Filtration Process High Quality Effluent for RO Feed
  • 8. ZeeWeed® MBR Influent Filtrate (Effluent) 10,000 to 15,000 mg/l Bioreactor Membrane (liquid/solids separation) Hi-Rate Biological Treatment • large capacity throughput • compact footprint • advanced treatment • simpler, more reliable process Absolute / Positive Filter • high degree of biomass/solids control • consistently high effluent quality • lower operator attention - less components 8
  • 9. ZeeWeed® MBR Technology • Immersed • Hollow fiber • Outside-in • Ultrafiltration (UF) • PVDF (chlorine and oxidant-resistant) polymer 0.04 µm 9
  • 10. ZeeWeed = Consistent High Quality Effluent Achievable ZeeWeed Treatment Results BOD5 < 5 mg/L TSS < 1 mg/L NH3-N < 0.05 mg/L TN < 3 mg/L* TP < 0.05 mg/L* Turbidity < 0.1 NTU SDI <3 * With appropriate biological design ** After disinfection 10
  • 11. Industrial Wastewater Reuse
  • 12. Specifics of Industrial Wastewater Reuse Treatment General Considerations! • Treatability of Wastewater or achievability of effluent requirements is always questionable! • Wastewater characteristics can be completely different from one application to next within same industrial segment
  • 13. Specifics of Industrial Wastewater Reuse Treatment • • • • • • • • • • Extreme pH variations Non (readily) biodegradable fractions (COD, organic N) Nutrient deficiencies (N, P, ions) Extremely high influent concentration (COD, N, P, etc.) High solids concentrations (TSS, VSS)/ inert material high temperatures high/ low TDS inhibitory compounds or toxic compounds other compounds to be considered for design, e.g. sulphides Foulants/ Scalants (colloidal material, free oil, scalants) Piloting is an essential tool for accurate design
  • 14. Automotive Industry Wastewater Reuse
  • 15. Automotive WW Treatment GM Tonawanda, NY, USA SMART Car, Hambach, France Ford Hermosillo, Mexico Ferrari Maranello, Italy
  • 16. The Coolest: Ferrari Maranello, Italy • Plant expansion & addition of new paint facility required an upgrade of the existing water treatment facility • Engineering consultants Fenice Spa & Desa Srl recommended MBR technology • GE MBR at Fiat Mirafiori’s plant had successfully demonstrated the technology in a similar application • 53,000 gpd • MBR configuration: 2 trains x 8 cassettes x 20 ZW 500c modules • Commissioned Jan 2004
  • 17. Toyota Kirloskar, Mysore Road Membrane Bioreactor Treatment Process Water Reuse in the process Design Flow: 860m3/day Influent Wastewater: • BOD: 100 mg/L • COD: 550 mg/L • TSS: 650mg/L Treated Effluent: • BOD: <5mg/L • COD: <30mg/: • TSS: <5mg/L Plant Commissioned 2011
  • 18. Volkswagen, Pune Membrane Bioreactor Treatment Process Water Reuse in the process Design Flow: 860m3/day Influent Wastewater: • BOD: 625 mg/L • COD: 1250mg/L • TSS: 350mg/L Treated Effluent: • BOD: <5mg/L • COD: <30mg/ • TSS: <5mg/L Plant Commissioned: 2010
  • 19. Refinery & Petrochemical Reuse
  • 20. PEMEX Refinery, Mexico Tertiary treatment of combined refinery effluent as pretreatment for RO Located in Minatitlan, Mexico at one of Mexico’s largest refineries (173,200 bpd) Wastewater treatment for reuse in the refinery – overall water recycle efficiency is 70% RO permeate reused for cooling tower makeup and lowpressure boiler feed Treatment capacity of 6.8 MGD Commissioned in November 2001 Drivers – process reliability, cost savings
  • 21. PEMEX Refinery, Mexico UF membrane process trains
  • 22. PEMEX Refinery, Mexico UF system performance data BOD (mg/L) Secondary effluent to UF 50 Treated effluent, RO feed <5 TSS (mg/L) 200 <1 Turbidity (NTU) 25 < 0.1 SDI (-) N/A < 3.0
  • 23. Membranes Immersed in Process Tank @ 85,000 mg/L FOG After Upset! Cassette Fully Restored After Recovery Cleaning!
  • 24. India Refinery Projects EIL – Engineering Consultant Reuse Influent API/TPI/DAF SBR Membrane Bio Reactor
  • 25. MBR Case Study: Refinery Wastewater BORL Bina Customer Challenge Treatment of refinery wastewater for reuse in process Application Wastewater Reuse Industry Refinery Capacity 9.0 MLD Location Bina, Madhya Pradesh, India Year of Commissioning 2008 Parameter System ZW MBR Membranes ZW 500 D Hollow fiber Outside- in Partner HDO Influent Effluent (Design) BOD 50 <5 COD 300 <20* TSS 100 <1 FOG 10 0 P 5 <1
  • 26. HPCL Refinery Owner Name HPCL Location: Mumbai System Type: ZeeWeed® MBR Membrane Type: ZeeWeed® 500 Flow Rate: 7.2 MLD Feed Source: Refinery Wastewater GE’s Discharge Requirement: BOD < 5 mg/L COD < 20* mg/L TN* < 7 mg/L Turbidity < 1NTU And other parameters Process: Nitrification/De-nitrification Commissioned: 2010
  • 27. HMEL Refinery Owner Name HMEL Refinery Location: Punjab System Type: ZeeWeed® MBR Membrane Type: ZeeWeed® 500 Flow Rate: 12 MLD Feed Source: Refinery Wastewater GE’s Discharge Requirement: BOD < 5 mg/L COD < 20* mg/L TN* < 7 mg/L Turbidity < 1NTU And other parameters Process: Nitrification/De-nitrification Commissioned: 2012
  • 28. India Petrochemical Wastewater Reuse Reliance Dahej PTA Effluent Treatment Influent Wastewater: • Membrane Bio Reactor Technology for Treatment and Reuse • COD: 1,300 – 1,500 mg/L Approximately 45 MLD in 4 different Modules will make it Largest MBR in Petrochemical Industry Expected Effluent Quality: • • Under Installation • BOD: 500 – 600 mg/L • TSS: 50 – 140mg/L • BOD: <5mg/L • COD: <30 - 40mg/L • TSS: ND Turbidity: ≤ 0.5 NTU (100% of the time) ≤ 0.1 NTU (90% of the time)
  • 29. Food & Beverages Wastewater Reuse
  • 30. Nestle Anderson, Indiana Nesquick/Coffeemate wastewater • $360M factory and distribution center for Nestle’s Beverage division • 880,000 square foot facility produces ready-to-drink milk products like Nesquick and Coffee-Mate products • Limited existing sewer flows • Downstream POTW capacity was insufficient to treat increased organic & solids load • Solution: 1.14 MGD MBR • Commissioned in Summer 2008 • Up to 80% of the MBR permeate is reused for nonproduct contact applications eg. cooling tower makeup
  • 31. Coca Cola, Puerto Rico Soft Drink Bottling Plant • New WWTP to treat increased bottling plant flow • High cost of WW disposal – trucked to POTW • Overdrawing existing well water supply • Solution: MBR (January 2004) + RO Bioreactor • Average flow / peak flow: 72,000 / 121,000 gpd • High influent flow variations and wastewater strength: – COD – up to 19,000 mg/L – BOD – up to 9,200 mg/L – TSS ~ 50 mg/L – TP ~30 mg/L • Achievement of total reuse of treated wastewater – 100,000 gpd water savings to plant – Economically feasible: savings far exceed costs Membrane skids
  • 32. Nestle India Plants • • • • • Nestle Manesar Nestle Himachal Nestle Moga Nestle SriLanka Nestle Panipat Design Flow Ranges from 250m3/day to 1,800 m3/day Influent BOD Range: 400 – 1,800mg/L Influent COD Range: 1200 to 4,000mg/L Treated Water being reused for process and cooling towers etc.
  • 33. Conclusions
  • 34. Conclusions Demands Exist for wastewater reuse in each type of industry Immersed hollow fiber membranes fit the need To treat industrial wastewater to the levels required for reuse Immersed hollow fiber membranes are the state-of-the-art In the treatment of “Tough To Treat” Wastewater for reuse Full-scale membrane facilities treating various Industrial wastewater exist Proving the technical feasibility of MBR Technology
  • 35. Questions?