This document discusses the implementation of an ozone oxidation system at a textile plant in Nairobi, Kenya to treat its wastewater. The current treatment process uses large amounts of chemicals but produces high TDS water. The proposed solution adds ozone treatment in the primary equalization tank to break down dye compounds before further treatment. This is expected to significantly reduce chemical usage and costs, lowering the operating costs by $23,725 per year. With a total project cost of $35,000, the return on investment is estimated to be 1.47 years or 18 months.

1. Textile Color
Waste Water
Ozone Oxidation
in Primary Stage
Spinners & spinners – Kenya - Textile color effluent
Case Study

2. INDEX
 1. Site Data
 2. Present Scenario
 3. Objective
 4. Offered Solution & Technology
 5. General Arrangement Drawing & PFD
 6. Implementation – Site Pictures & Video
 7. Operation & Maintenance
 8. Consumables & Replacements
 9. Savings
 10. Return On Investment [ROI]

3. Site Data :
Site Location : Nairobi - Kenya
ETP Capacity : 100 KLD
Present Treatment : Physico-Chemical Process
Present Process Scheme : Equalization + Chemical Dosing +
Coagulation + Flocculation + Clarifiers
+ Sand Filter + Carbon Filter

4. Present Scenario :
Color effluent from textile plant :
Raw color waste water is collected in equalization tank from different
areas. High quantity of chemicals are used to treat this color effluent
to make it colorless & then recycled back in process. Due to addition
of chemicals TDS of water goes on increasing & due to this blow
down water quantity is high. Also due to use of chemicals, operating
cost & cost of recycled water is high.

5. Objective :
Enhance Recycled quality of water
Reduce Chemical Consumption to reduce Operating cost.
Implement Environmental Friendly Technology
Higher degree of Compliance

6. Offered Solution & Technology :
Ozonation in equalization tank – Primary stage
Ozone is a very strong oxidizing agent.
Ozone react much faster than any other oxidizer.
Ozone can efficiently break complex molecular bond.
Ozone enhances coagulation & flocculation.
Crucial part of the solution is to integrate ozone in
existing scheme with optimum ozone dose.

7. Process
Flow
Diagram

8. G. A.
Drawing

9. Implementation :
Ozone
Generator
Plant Room
Raw Effluent
Collection Cum
Equalization
Tank 3
Raw Effluent
Collection Cum
Equalization
Tank 1
Raw Effluent
Collection Cum
Equalization
Tank 2

10. Implementation : Ozonation Plant Room
Cooling Tower
for Ozone Cell
Cooling
Water Cooled
Ozone Generator
150 G/hr
For Safety
Back Flow
Preventer
Oxygen
Concentrators

11. Implementation : Flow Direction
Submersible
Pump
Ozone
Connecting
Flexible Tubing
Ventury
Injection
Waste Water
Flow From 3rd
Equalization
Tank to 1st, via
Ventury, where
Ozone in Dossed

12. Implementation : Ozone Mixing in Circulation Mode
Effect Of Ozone Can be
seen in first tank, where
complex molecular bonds
of Organic & Reactive dies
are broken into simpler
chemical bonds.

13. Savings & Returns On Investments [ROI] :
Chemicals
Chemical
Specification
Quantity Per Day Rate
Per
Unit
Cost Per Day
SavingsBefore
Ozonation
After
Ozonation
Before
Ozonation
After
Ozonation
Name Kg or Ltrs Kg or Ltrs KS KS KS KS
Chlorine 45 25 180 8,100 4,500 3,600
Ph Adjust NaOH 10 10 70 700 700 -
Coagulant 25 - 90 2,250
-
2,250
Flocculent 0.4 0.4 716 286 286 -
Total Cost
Per Day
11,336 5,486 5,850
Total Cost
Per Year
4,137,786 2,002,536 2,135,250
Savings in
USD per Yr
45,975 22,250 $ 23,725
Ozonation Project Cost in USD [Including Supply + Wooden Packing + Air Freight + I & C] $ 35,000
Return On Investment [In Years] KS – Kenya Shilling 1.48

14. Savings :
Ph Correction Chemical : 0 %
Chlorine : 44 %
Coagulant : 100 %
Flocculent : 0 %

15. Benefits :
 Reduction In Chemical Cost – Reduction in OPEX
 Less Storage, Transport & Handling – Space & Time saving
 Higher Quality of Treated Waste Water
 Lower Operational Time – [Higher Plant Capacity]
 Higher Recovery – Less Blow Down [Lower Waste Water TDS]
 Lower Sludge Formation & Handling

16. Return On Investment:
 Savings Per Year : $ 23,725
 Total Capital Cost : $ 35,000
 Return On Investment : 1.47
 ROI : 18 months

17. Operation & Maintenance :
 Ozonator is fully electrical operated. [No Consumables]
 Ozonator should be operated 24 x 7
 Routine maintenance frequency is once in months
 Break-down repair/maintenance will be attained in 48 hrs.
(Depending on site criticality & reliability of equipment, standby
units are recommended)

18. Consumables & replacements :
 Consumables : Electricity Power - 4.5 Kwatt
 Electrical consumption : 2.0 kw x 24 hrs = 48 kw-hr
Replacements:
 Ozone cell : 2 – 2 ½ yrs : $ 1,000
 No. of Ozone Cells : 02 nos.
 Molecular sieves : 1 ½ - 2 yrs : $ 400
 No. of Sets (Mol. Sieves) : 04 nos.

19. Thanks For your Precious time
For more Information :
Visit : www.chemtronicsindia.com / www.ozonegeneratorindia.com
Email: sales@chemtronicsindia.com
Call / Whatsapp : Mr. Sunil Shah - +91-9321234527
Skype : sunilshah.chemtronics