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
•
•
•
•
•
•
•
•
•
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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
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•
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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?