2. 2
Zero Liquid Discharge (ZLD) –
• Introduction
• History
• System Overview
ZLD in Indian Industries –
• Policy Scenario
• ZLD Evolution
• ZLD Cost Comparison
• ZLD Value Chain
ZLD in Indian Textile & Apparel Industry
• Impact of ZLD
• ZLD Market Opportunity
• Case Study – Tirupur
List of ZLD Experts and Related Technology
Contents
3. 3
Zero liquid discharge is a process that is beneficial to industrial and municipal organizations as well as the environment because it
saves money and no effluent, or discharge, is left over.
ZLD systems employ the most advanced wastewater treatment technologies to purify and recycle virtually all of the wastewater
produced.
Also Zero liquid discharge technologies help plants meet discharge and water reuse requirements, enabling businesses to:
• Meet stringent cooling tower blowdown and flue gas desulfurization (FGD) discharge regulations.
• Treat and recover valuable products from waste streams.
• Better manage produced water.
A Zero liquid discharge facility (ZLD), is an industrial plant without discharge of wastewaters. Target ZLD is normally reached by
• Waste water strong recovery
• Separation by evaporation or boiling of water part of waste water not reusable, in evaporators,
crystallizers and condensate recovery. ZLD plants produce solid waste.
Zero Liquid Discharge
4. 4
ZLD sector was apparently born in 1970s in USA, driven by the regulator
• Tight federal regulations on salt discharge to surface waters introduced, especially, due to salinity problems in the Colorado River
• Regulations were mainly concerned with power plant discharges from cooling tower blowdowns and scrubbers (in the wake of
previously introduced regulations on flu gas discharges)
• Clean Water Act 1974, revised 1977, 1982
First ZLDs installed were 500‐2,000 GPM units based on evaporation/crystallization
Regulations are expected to keep tightening: new EPA’s guidelines (ELG) expected in 2017 and 2022 on various types of discharges
many have to be ZLD.
Zero Liquid Discharge - History
5. 5
ZLD System Overview –
• ZLD technology includes pre-treatment and evaporation of the industrial effluent until the dissolved solids precipitate as crystals.
• These crystals are removed and dewatered.
• The water vapor from evaporation is condensed and returned to the process.
• The state of Tamil Nadu in India has made ZLD mandatory for all its industries.
Configuration –
• Normally the evaporation-crystallizing section receives the reject from a reverse osmosis section that concentrates dissolved
solids.
• To prevent fouling during the reverse osmosis process, ultrafiltration is often used to eliminate suspended solids.
Zero Liquid Discharge – System Overview
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How Can You Achieve Zero Liquid Discharge (ZLD) - Video
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Zero Liquid Discharge (ZLD) guidelines were recently introduced for four industrial sectors in India.
These sectors would be required to set up systems which will treat the waste water as well as recover dissolved chemicals so that
water can be again used in factory operations.
These sectors are;
• Textile (wet processing)
• Tanneries
• Distilleries
• Pulp & Paper (Zero Effluent Discharge mandate)
This segment brief provides insights to the following questions:
• What is current policy scenario for ZLD in India?
• What is the value chain associated with ZLD system?
• What are the key drivers and challenges for ZLD in different
industry segments? (for this we have focused on 3 segments that
have the most number of units- namely Textiles, Paper& Pulp and Pharmaceuticals)
Zero Liquid Discharge in Indian Industries
ZLD in India
Textile (wet
processing)
Tanneries
Distilleries
Pulp &
Paper (Zero
Effluent
Discharge
mandate)
9. 9
Till now the whole ZLD issue in textile was limited to Tirupur and the Bulk drug manufacturers in Andhra Pradesh, but now focus on Zero
Liquid Discharge had come to the forefront following the launch of the “Namami Gange” program last year.
This is part of the election commitment made by the present Indian government to clean the river Ganga, one of the key rivers flowing
through the country.
Our study showed that the regions that are most likely to be affected by Zero Liquid Discharge legislation in the near future would
include areas that are facing ground-water scarcity issues as well as those worst affected by industrial water pollution.
We had identified 10 states- (Uttar Pradesh, Punjab, Delhi, Gujarat, Rajasthan, Haryana, Madhya Pradesh, Andhra Pradesh,
Maharashtra and Jharkhand)
As further details are hammered out, industries can expect to be mandated to better manage their effluent discharge, not only in the Ganga
Basin but across the country in the near future.
Zero Liquid Discharge in Indian Industries - Policy scenario
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Evolution of the policy mandate for Zero Liquid Discharge (ZLD) in India –
Zero Liquid Discharge in Indian Industries
Tamil Nadu was the first state in India to mandate ZLD in the textile sector back in 2008. In 2011 due to failure textile factories to comply with the
mandate, all the industries were shutdown based on the order from the state’s High Court.
It took one and a half year for industries to finally implement ZLD in their factories and start operations again. The whole process was brutal
and many players either moved out of the region, others had to shut down their business altogether.
Those that survived have set the stage for what it means to operate with very limited water
In 2013, Andhra Pradesh Pollution Control Board (APPCB) issued notices to Dr. Reddy labs and other bulk drug manufacturing
companies in Hussainsagar area to stop polluting the ground water resources and achieve Zero Liquid Discharge.
The companies complied and this also helped them in compiling to USFDA norms which was the added benefit for the export oriented
sector.
Till now the whole ZLD issue in textile was limited to Tirupur and the Bulk drug manufacturers in Andhra Pradesh, but now focus on Zero
Liquid Discharge had come to the forefront following the launch of the “Namami Gange” program last year.
This is part of the election commitment made by the present Indian government to clean the river Ganga, one of the key rivers flowing through
the country.
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Evolution of the policy mandate for Zero Liquid Discharge (ZLD) in India –
Zero Liquid Discharge in Indian Industries
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Evolution of the policy mandate for Zero Liquid Discharge (ZLD) in India –
• The graph below indicates the number of grossly water polluting industrial units along the Ganga basin
• Uttar Pradesh being the largest state has the most number of water polluting units which includes 440 tannery units in Kanpur
region.
Zero Liquid Discharge in Indian Industries
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Summary of Zero Liquid Discharge guidelines –
Zero Liquid Discharge in Indian Industries
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Outlook for the policy agenda –
• When the initial focus on Zero Liquid Discharge had come to the forefront following the launch of the “Namami Gange” program
last year, Sustainability Outlook had carried out an analysis on the prospects of ZLD in Indian industry (read here).
• The analysis found that globally, as in India, the primary driver for an expensive technology like ZLD would be legislation.
• 10 states- (Uttar Pradesh, Punjab, Delhi, Gujarat, Rajasthan, Haryana, Madhya Pradesh, Andhra Pradesh, Maharashtra and
Jharkhand) which would be most likely to see stricter water-pollution legislation in the near future.
• The recent policies seem to be following the trend that was predicted.
• These legislations all seem to point at the same story - it seems that India is finally waking up to the acute water crisis we are
likely to face in the future in a business as usual scenario.
• The steps taken by various authorities will galvanize the market for waste water treatment technology and present a great
opportunity for manufacturers of Zero Liquid Discharge technology as well as sewage and effluent treatment plants and a result
in high investments in the water sector.
• Global players like VA Wabag and Veolia Water have already started entering the Indian market with Maharashtra proving to be
the production hub with twelve companies already setting up base in the state.
Zero Liquid Discharge in Indian Industries
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High operating costs due to high energy consumption is one of the key challenges; Economies of scale may help reduce it
• High operation cost is currently the biggest barrier in implementation and success of ZLD system.
• Currently reverse osmosis and evaporation are the most used solutions for zero liquid discharge.
• These equipment have a high operational cost due to high energy (thermal and electrical) consumption.
Zero Liquid Discharge in Indian Industries
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Uniform application of the ZLD policy would be key for getting buy-in
• Since ZLD has high impact on product cost, this may reduce the cost competitiveness of factories in these areas compared to
other areas. As shown in the chart below the increase in the production cost with and without ZLD is between 14% and 42%.
• Hence, unless policy is uniformly applied, this will effectively make factories shift to other areas (and pollute freely there) to stay
competitive rather than installing ZLD plant in their facility.
Zero Liquid Discharge in Indian Industries
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Generally Zero Liquid Discharge is a combination of multiple
water treatment systems.
To understand the value chain, we must first understand the
Zero Liquid Discharge system and the various technologies
and their characteristics. ZLD value chain consists of consists
of six main components.
The diagram below provides an overview of the ZLD process
Understanding the ZLD value Chain
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Different components of the Zero Liquid Discharge Value Chain are as follows;
• Treatment equipment manufacturers
• Recycle/recovery equipment manufactures
• Water Supply
• Sludge handlers
• Toxic waste handling companies
• Auxiliary equipment and consumables suppliers
Understanding the ZLD value Chain
Treatment
equipment
manufacturers
Recycle/recovery
equipment
manufactures
Water Supply
Sludge handlers
Toxic waste handling
companies
Auxiliary equipment
and consumables
suppliers
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Treatment equipment manufacturers (Step 2 listed above)
• It consists of companies which manufacture and operate effluent treatment plants, primarily biological and physiochemical
treatment plants. Noticeable names in this field are, Xylem, Wipro water, United Waters India Ltd. etc
Recycle/recovery equipment manufactures (Step 3 listed above)
• This includes manufacturers of recovery equipment like Reverse Osmosis plant manufacturers, Evaporator and crystallizer
suppliers etc. Now a days many companies that provide primary treatment solutions also provide recovery equipment's.
Noticeable examples are, Arvind Envisol, Aquatech, Praj Industry, Wabag, Doshion Veolia, Giest Woow etc.
Water Supply (Additions to Step 1 listed above)
• Although ZLD recovers most of the water there is still a 5-7% loss due to evaporative loss and leakage.
• For this companies have to add make up water which can either be bought from water supply companies predominantly water
board owned by municipal authorities or in some cases where ground water withdrawal is allowed by the local government
companies can directly withdraw water from ground water resources.
Understanding the ZLD value Chain
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Solid waste handling for different stages
• Sludge handlers
‐ After initial treatment (Step 2), sludge of different forms get generated depending on the input water quality. Depending on
the level of toxicity different firms have to be engaged for picking up the sludge.
• Toxic waste handling companies
‐ These are either government approved or pubic private partnership companies which safely dispose the highly toxic reject
from the evaporator or solar pond. E.g. Tamil Nadu Waste management company disposes the toxic waste from many
Tirupur textile ZLD plants.
Auxiliary equipment and consumables suppliers
• Many chemicals are used in the treatment process E.g. Hydrochloric Acid (HCl) for pH treatment. Other consumables are
membranes used in Ultra Filtration (UF), Nano Filtration (NF), Reverse Osmosis (RO), Membrane Bio Reactor (MBR) etc.
• As pumping and pipe networks are required in every ZLD plant, they are only available at OEM suppliers.
• Also plant automation and electricals are essentials for the smooth running of the plant which is done by companies like
Schneider and ABB.
Equipment suppliers
• The figure below gives a snapshot of various players according to their role in the value chain.
Understanding the ZLD value Chain
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The selection of technologies depends upon the composition of effluent as different technologies remove different contaminants at
different rates.
Different Technologies that constitute a Zero Liquid Discharge system
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Key drivers for uptake of Zero Liquid Discharge in different industrial segments
• Water scarcity
• Notification from state pollution control board
• Resource recovery
Challenges for implementation of Zero Liquid Discharge in different industrial segments
• High initial capital expenditure and even higher operating expenditure
• Management of highly toxic waste which is the by-product of treatment process.
• Space requirement.
• Impact on cost of final product.
Different Technologies that constitute a Zero Liquid Discharge system
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Applicability of ZLD in industries like Pulp & Paper, Pharmaceuticals and Textiles –
• Contaminants in the effluent vary from industry to industry and different technologies are designed to separate different
pollutants and different separation rate.
• Also cost of separation also plays a major role in selection of technology for the ZLD system.
• Estimated the impact of Zero Liquid Discharge treatment on the cost of final product.
• Some of the key findings were;
‐ Textile: ZLD mainly impacts a part of the textile value-chain which is focused on dyeing and colouring; increasing their cost by
6-10%
‐ Pharmaceutical: High quality standards are limiting the sector to do only partial ZLD
‐ Pulp & Paper: The industry needs to focus on reducing Specific Water consumption currently and then move to ZLD
ZLD in Indian Textile Industry
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TEXTILE: ZLD mainly impacts a part of the textile value-chain which is focused on dyeing and colouring; increasing their cost by 6-
10%
• Textile industry in India has had experience in Zero liquid Discharge systems since 2008 when Tamil Nadu high court mandated
Zero Liquid Discharge systems for dyeing and wet processing industry in Tirupur.
• It showed that almost 92-95% water recycle is possible in textile industry with recovery of salts which can be again used for
dyeing process.
• Some of the factories over here are using ZLD system for almost 5 to 10 years and they have gathered enough expertise to
optimize and reduce the operating cost by a certain extent.
• Due to the high use of dyes the effluent form textile industry contains pigments, ions due to salts used in dyes.
• Therefore the recommended configuration for textile effluent is Pre-treatment with Biological treatment and adsorption,
chemical precipitation to remove ions followed by reverse osmosis which recovers 80% of water.
• The remaining 20% is sent to Multi-Effect Evaporator (MEE) or combination of Mechanical Vapour Recompression Evaporator
(MVR) and MEE for further separation.
ZLD in Indian Textile Industry
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The various technology options for zero liquid discharge in textile are as follows –
ZLD in Indian Textile Industry
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High operating cost at a factory level is a major pain point
• Capex for the ZLD plant is not as significant as compared to the OPEX in terms of ZLD due to high energy consumption. For a
typical 1000KLD plant, the CAPEX is about Rs. 6 Crores but the OPEX to run it for just 6 years is almost 3 times of the CAPEX.
• The operating cost ranges from Rs. 150 to 200/KL depending on following factors
‐ % recovery in RO
‐ Type of the chemicals used
‐ Fuel used in boilers to generate steam
‐ Amount of COD waste generated
‐ Amount of toxic waste generated
ZLD in Indian Textile Industry
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Outlining Tirupur Experience: Value of resource recovered
• In case of textiles majority of resources recovered are water and salt used in dying process.
• The water cost in Tirupur is Rs. 70/KL. So if factories recover 100% of water then the effective resource saving should be Rs.
70/KL.
• Although due to the limitation of technology actual recovery ranges from 80% to 95%.
• Therefore factories have to buy the makeup water which brings down the value of water saved to almost Rs. 40 – 60/KL
• Salt used is mostly glober salt which costs about Rs. 10/KL.
• Depending upon the use 95 to 98% pure salt can be recovered.
• In some cases concentrated brine solution is recovered and used for dyeing process.
• The combined value of recovery for brine and salt ranges from Rs. 15–60/KL
• It is evident the value of resources recovered through ZLD process is not enough to cover the total cost of the project.
• After taking account value of various resources recovered the cost of water comes down to Rs. 30 – 70/KL in case of Central
Effluent Treatment Plant (CETPs) and Rs. 120 – 130/KL in case of Independent Effluent Treatment Plant (IETPs).
• Although this might be the case in country like India where industrial water is insufficiently priced which provides the false
picture of the tangible savings incurred due to ZLD systems.
ZLD in Indian Textile Industry
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Impact on the Final product –
• While the impact on the textile mills that dye and
colour the fabric is high, the impact of the ZLD cost on
the final cost of the product is minimal.
• In the textile supply chain, increase in water cost
majorly affects the wet-processing but does not have
a substantial impact on overall end product pricing.
• The impact of ZLD on a shirt would be less than 1%
impact on the end product pricing for a short that
cists Rs 6.5/250 gms.
• However, the manufacturers and the marketers have
yet to agree on being able to pass on this cost to
the consumers.
ZLD in Indian Textile Industry
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Zero Liquid Discharge will change the way industry thinks about water
• Traditional thinking is that wet processing units should be located in areas with sufficient water. This assumption will not hold
true in future for the following reasons:
• In many cases there are competing uses of water that have more pressing needs: mainly agriculture and drinking.
• The ‘value addition’ of water by the wet-processing industry is lower in comparison with many other industries that also
generate higher economic value for the same water. This includes sectors such as automotive, pharmaceuticals, processed food,
etc.2
• Increasing water scarcity in many regions only reinforces the direction towards the first two.
In the future wet-processing and water-availability will get delinked.
Near term focus on systems and effectiveness
• In the near term, the focus is going to be on
• (a) increasing the effective use of resources and
• (b) developing systems to create roadmaps for continuous resource reduction.
• This would be similar to other supply-chain intensive sectors (auto, white-goods, consumer-products, pharma) where buyers and
suppliers are constantly reducing resource usage of products.
Impact of Zero Liquid Discharge
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Longer term change in outlook
• There can also be a longer term vision as we believe that wet-processing would transform in 10 years. Some changes that would
happen:
Impact of Zero Liquid Discharge
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The Rising Tide of ZLD in India: Key Accelerators for the Market
• Traditional thinking is that industrial units should be located in areas with sufficient water. This assumption will not hold true in
future.
• The actual market for ZLD across industrial sectors would depend on a variety of drivers, such as the policy scenario, water status
of the region, increasing the industrial water productivity and recovery of valuable resources such as water, salts and other by-
products.
Policy is the Biggest Driver for ZLD
• ZLD is not a completely new concept in India and was first introduced in the country in 2006, with Madras High Court and Tamil
Nadu Pollution Control Board (TNPCB) directing the textile dyeing and bleaching units in Tirupur to achieve ZLD.
• Central Pollution Control Board (CPCB) having identified 17 highly polluting industries for achieving ZLD in 9 Ganga basin states,
has mandated textiles, distilleries, tanneries, chemicals, fertilizers, pesticides, dyes and pharmaceuticals in the first phase of the
Ganga Action Plan in 2015.
• Moreover, with the draft national mandate for ZLD in Textile (wet processing) and fermentation already released, it is expected
that ZLD would be extended across other sectors and geographies in the near future, hence causing a surge in demand for ZLD.
ZLD Market Opportunity in Indian Industry
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Key Challenges Plaguing Implementation
• Despite the strong policy push and case due to acute water scarcity in certain regions, ZLD implementation has a few challenges.
These include:
‐ Low Price of water leading to weak business case
‐ High cost of implementation leading to reduced cost competitiveness in the national and global markets
‐ Lack of financing sources
‐ Disposal of solid by-product in certain sectors
‐ Escalated carbon footprint of the industry
‐ Technology limitations
• In order to smoothen out the implementation pressures and drive the action agenda, focus can be on models of operation and
capacity building of operators within industrial units.
ZLD Market Opportunity in Indian Industry
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INR 210 billion (USD 3.2 billion) Market Potential for ZLD Solutions in Textile, Distilleries and Pulp & Paper Industry by 2020
• The cumulative market potential across the three sectors of focus in 2020 would be nearly INR 210 billion (USD 3,182 million),
with investment in ZLD for Textile (wet processing) constituting the largest chunk of market at approximately INR (x) billion (USD
(y) million).
• The market size for key components of ZLD system, i.e. Reverse Osmosis (RO) is INR (x) billion (USD (y) million) and that for Multi
Effect Evaporator (MEE) is INR (x) billion (USD (y) million) by 2020.
ZLD Market Opportunity in Indian Textile Industry
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ZLD Increases Cost of Textile Wet Processing by 8-10% but that of Final Product by Less Than 1%
• Implementation of ZLD is likely to increase the cost of dyeing fabrics by INR 15-20/kg and therefore has a does have a
considerable impact (8-10%) on cost of product in the wet processing segment of the textile value chain.
• The industry can recover water and salts, which may help improve the economics depending on the price of water in different
states. However, the textile sector as a whole has a considerably good business case for ZLD as the impact on the end product for
the sector is not very significant.
• In the textile supply chain, increase in water cost majorly affects the wet-processing but does not have a substantial impact on
overall end product (garment in this case) pricing.
• The impact of ZLD on a shirt would be less than 1% impact on the end product pricing for a shirt that costs INR 6.5/250 g.
ZLD Market Opportunity in Indian Textile Industry
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Due to the high cost there is a strong motivation to employ more energy saving process to minimize the MVC/Crystallization share.
(Compare with costs of desalination technologies: RO << ED << Thermal.)
• Reverse Osmosis* (RO) – rejects salt, passes water, 2‐4 kWh/m3
• Nanofiltration* (NF) – similar to RO, but passes some salt
• Electrodialysis* (ED) or ED reversal (EDR) – removes ion, costs intermediate to RO and MVC
• Natural Evaporation – slow, large footprints
Another possible motivation is presence of organics, volatiles, colloids etc., which complicates the treatment and water reuse.
Available solutions:
• Conventional bioremediation
• MBR/UF pre-treatment
Hybrid ZLD Technologies
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RO is presently the best and most energy‐saving available technology for desalting.
The purpose is then to use RO to recover as much water as possible before MVC.
The ZLD cost drops as RO recovery increases.
• The recovery in RO is however limited by 3 main factors
• Osmotic pressure becomes too high for TDS ~ 80,000 ppm
• Scaling by sparingly soluble salts (Ca, Mg, SO4, PO4, silica), maybe alleviated to some degree using anti‐scalants
• Fouling (by organics, colloids, biofilms etc.
ZLD Combined with RO
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Veolia Water Technologies, North America –
• HPD® Evaporation and Crystallization system capacities range from around 10 gpm to greater than 1500 gpm per unit.
• It also has several proprietary Innovations that make thermal ZLD systems more affordable and robust.
• These include the CoLD® Crystallization Process for produced/flowback water from fracking and FGD blowdown, the Silica
Sorption process for produced waters from SAGD and steam flood stimulation techniques, and the Modular Bulldozer Design
evaporation/crystallization system for coal seam gas produced water and other challenging wastewater applications.
GE Power, Water & Process Technology, USA –
• ZLD Crystallizers –
‐ In order to meet stringent zero liquid discharge (ZLD) requirements, environmentally conscience companies are turning to
advanced technologies that eliminate wastewater streams and leave behind clean water and solid salt crystals.
‐ Combined with other brine concentration technologies such as evaporators, crystallizers concentrate the wastewater to a
solid that can be safely disposed of in a landfill or recovered as a valuable by-product for use.
• Pure Product Crystallizers
• SAGD Water Evaporators
• Wastewater Evaporators
Experts in ZLD Technology
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Aquarion –
• ZLD CLASSIC
‐ In the classic Zero Liquid Discharge process, the waste-solutions obtained from a process are completely evaporated until
only solid waste remain.
• ZLD CURRENTLY
‐ In this slightly more sophisticated technology, multiple processes are combined in order to partially replace the thermal
process. Usually a portion of the liquid waste are pre-concent-rated by membrane technologies. This reduction of the feed
stream to the evaporator leads to lower operating and investment costs.
• ZLD – ECO
‐ AQUARION optimized further the ZLD process by introducing advanced pre-treatment processes that reduce thermal
treatment to a minimum. This leads to lower energy and chemical consumption (cooling, heating and electrical energy) and
reduced capital cost. Modular and compact designs with short production times are integrated into our holistically designed
process plants.
• ZLD - ECO2
‐ Aquarion is focused on constantly improving the efficacy and cost-effectiveness of ZLD solutions. Based on the technologies
used, ZLD.eco2 is one of the most reduced cost ZLD systems available today.
Experts in ZLD Technology
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Degremont Technologies –
• ZLD Specific Technology
‐ 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.
‐ Falling film evaporation is an energy efficient method of evaporation, typically to concentrate the water up to the initial
crystallization point. The resultant brine then enters a forced-circulation crystallizer where the water concentrates beyond the
solubility of the contaminants and crystals are formed.
‐ The crystal-laden brine is dewatered in a filter press or centrifuge and the filtrate or centrate (also called “mother liquor”) is returned
to the crystallizer. The collected condensate from the membranes, falling film evaporator and forced-circulation crystallizer is
returned to the process eliminating the discharge of liquids.
‐ If any organics are present, condensate polishing may be required for final clean-up prior to reuse.
• INFILCO Zero Liquid Discharge System Overview
‐ ZLD technology includes pre-treatment and evaporation of the industrial effluent until the dissolved solids
precipitate as crystals.
‐ These crystals are removed and dewatered. The water vapor from evaporation is condensed and returned
to the process.
‐ This process may utilize all or part of five S.M.A.R.T. Zone™ engineering modules including pre-treatment,
membrane filtration, evaporation, crystallization and solids recovery. Each module can be executed in
parallel to expedite the design and implementation process.
Experts in ZLD Technology