Designing Zero Discharge System for a

Textile Waste Water Treatment Plant

ecp consulting
infusing intelligence
S.ESWARAMOORTHI
Scientific & Technical Consultant
18
th
January 2010
TABLE OF CONTENTS
Section Content Page
1 INTRODCTION !
2 CO""#CTION $ND CON%#&$NC# !
! PROPOS#D TR#$T'#NT SC(#'#S )
!*1 Treating Segregate+ an+ Co,-ine+ Ra. #ffluent )
!*2 Pri,ary Treat,ent Syste, /
!*! Secon+ary Treat,ent Syste, 8
!*0 Tertiary Treat,ent Syste, 1
0 OPTI'I2$TION O3 S&ST#' D#SI4N $ND
P#R3OR'$NC#
10
) R#SORC#S N##D#D5R#6IR#'#NTS 11
/ NIT PROC#SS#S 12
LIST OF ABBREVIATIONS
$C3 $cti7ate+ Car-on 3ilter
8OD 8iological O9ygen De,an+
C#TP Co,,on #ffluent Treat,ent Plant
COD Che,ical O9ygen De,an+
388R 3lui+i:e+ 8e+ 8ioreactor
(RT (y+raulic Resi+ence Ti,e
'8R 'e,-rane 8ioreactor
'"SS 'i9e+ "i;uor Sus<en+e+ Soli+s
OT# O9ygen Transfer #fficiency
PS3 Pressure San+ 3ilter
S8R Se;uencing 8atch Reactor
SRT Soli+s Retention Ti,e
TDS Total Dissol7e+ Soli+s
TSS Total Sus<en+e+ Soli+s
$S8 <flo. $naero-ic Slu+ge 8lan=et
%OC %olatile Organic Co,<oun+s
#CP CONS"TIN4 Page>2 ...*ec<consulting*in
DESIGNING ZERO DISCHARGE SYSTEM FOR A TEXTILE
WASTE WATER TREATMENT PLANT
S.ESWARAMOORTHI
1
#CP CONS"TIN4
1. INTRODUCTION
The conce<t of :ero +ischarge i,<lies that the <rocess .ater utili:e+ in +yeing an+ -leaching
o<erations is reco7ere+ for reuse to an e9ten+ that no +ischarge of effluent into the en7iron,ent is
achie7e+* (o.e7er? there ,ay -e soli+ .astes generate+ in the <rocess an+ that shoul+ -e store+ in
a secure+ lan+fill* The ,ain o-@ecti7e of :ero +ischarge treat,ent syste, is ,ini,i:ing the effect of
.aste .ater on the en7iron,ent as far as <ossi-le*
$ny :ero +ischarge treat,ent syste, +esign shoul+ consi+er the follo.ing facts5re;uire,entsA
1* 6uantity of the effluent to -e treate+*
2* %aria-ility in ti,e of the ;uantity as .ell as ;uality of the effluent*
!* nit <rocesses suita-le for achie7ing +esire+ <ur<oses Bsuch as re,o7al of total sus<en+e+
soli+s CTSSD? re+uction in -iological o9ygen +e,an+ C8ODD? etc.E for the gi7en nature of the
effluent*
0* The u<<er an+ lo.er li,its of <erfor,ance of each unit <rocess*
)* The +ura-ility of the syste, to -e a+o<te+*
/* The feasi-ility of esta-lishing suita-le collection an+ con7eyance syste, in the case of a
co,,on treat,ent facility*
2. COLLECTION AND CONVEYANCE
Only little attention is <ai+ to.ar+s the +esign of a collection an+ con7eyance syste,* (o.e7er? its
role is 7ery ,uch i,<ortant for the successful o<eration of a :ero +ischarge treat,ent facility
2
*
So,e of the +esign as<ects of a collection an+ con7eyance syste, suita-le for te9tile .aste .ater is
consi+ere+ here*
1* Pro<ose+5a7aila-le location for the co,,on effluent treat,ent facility? e9ten+ of lan+
a7aila-le? an+ the <ossi-ility for further e9<ansion are to -e consi+ere+* The locality shall
+eter,ine the total length of the <i<eline re;uire+? its route? re;uire+ slo<e? <lace,ent for
air>loc= release 7al7es? an+ location of a++itional collection su,<s Cif foun+ necessaryD.
2* "e7elling sur7ey shoul+ -e con+ucte+ to esti,ate the latitu+e? longitu+e an+? height a-o7e
'ean Sea "e7el C'S"D of each ,e,-er unit an+ that of the <ro<ose+ co,,on effluent
treat,ent <lant CC#TPD* This infor,ation is i,<ortant to stu+y the feasi-ility of achie7ing
gra7ity flo. for effluent trans<ort? as .ell as in the +esign of treate+ .ater su<<ly lines to
the ,e,-er units fro, the C#TP*
1 e>,ailA infoFec<consulting*in
2 Refer Pipeline Design for Effluent Transport in Common Effluent Treatment Plants, a7aila-le for +o.nloa+ fro,
...*ec<consulting*in? for a ,ore +etaile+ +iscussion*
#CP CONS"TIN4 Page>! ...*ec<consulting*in
!* #sti,ation of ;uantity of effluent generate+ <er +ay in each ,e,-er unit is essential* $lso?
an assess,ent shoul+ -e ,a+e a-out the nor,al an+ <ea= flo. fro, each ,e,-er unit* If
any ,e,-er unit is o<ting to e9<an+ their +ischarge ca<acity in the future? that shoul+ also
-e ta=en into account* 8ase+ on this assess,ent? each ,e,-er unit shoul+ -e allocate+ a
,a9i,u, +ischarge that shoul+ ne7er -e 7iolate+ for any reason*
0* #sti,ating the a7aila-le storage ca<acity of effluent storage tan=s at each ,e,-er unit is
also essential* The <ro7ision for in+i7i+ual storage tan= at each ,e,-er unit achie7es
se7eral thingsA iD re+uces the +egree of <ea= flo.G iiD allo. the effluent to cool +o.n to
a,-ient te,<erature so that the <i<eline is not affecte+ G iiiD i,<ro7es ho,ogeni:ation that
re+uces the occurrence of shoc=s in the e;uali:ation tan= of the C#TP .hich hel<s in
,aintaining the sta-ility of the treat,ent syste,G i7D a-ility to store e9tra effluent +uring
<i<eline an+ C#TP ,aintenance o<erations? etc.
)* Pro7ision for re,o7al of +e-ris? grits? an+ sus<en+e+ soli+s shoul+ -e gi7en at each ,e,-er
unit
!
*
/* Te,<erature range of the effluent that ,ay get into the <i<eline an+ the ca<acity of the
<i<eline ,aterial to .ithstan+ this te,<erature range is to -e consi+ere+*
H* The +ura-ility of the ,aterial of construction of the <i<eline is 7ery ,uch essential* $s
+igging for <i<eline is a te+ious <rocess an+ that re;uires <rior a<<ro7al fro, 7arious
go7ern,ental agencies? the +ura-ility of the chosen <i<eline shoul+ fall so,e.here aroun+
!0 to )0 years* So,e of the i,<ortant re;uire,ents for a goo+ an+ efficient <i<eline are iD
the a-ility to .ithstan+ -urial <ressure an+ o<erating <ressure? iiD a-ility to .ithstan+
corrosion -y the effluent? iiiD a-ility to <ro7i+e an+ ,aintain s,oother inner surface o7er a
<erio+ of ti,e that re+uces retar+ation to the flo. an+ energy re;uire,ent? i7D a-ility to
han+le <ea= loa+s? 7D a-ility to han+le e9<an+e+ flo. as <er e9<ecte+ future +e,an+s? 7iD
characteristics a,ena-le for easy @ointing an+ -en+ing? etc.
8* $s assess,ent a-out <ro<ose+5a7aila-le <i<eline route .ith a list of e9isting natural an+
,an>,a+e i,<e+i,ents such as roa+s? rail.ay lines? ri7ers? .ater logge+ areas an+ -ri+ge
crossings? an+ <ro9i,ity to alrea+y e9isting <i<elines > es<ecially that of +rin=ing .ater
lines I ha7e to -e ,a+e*
1* $ccessi-ility to roa+? a7aila-ility of electric <o.er? <ro7ision for secure+ lan+fill
0
? <ro9i,ity
to ur-an <o<ulation
)
an+ archaeological treasures
/
shoul+ also -e ta=en into account*
10* The collection an+ con7eyance syste, shoul+ consi+er the i,<le,entation of gra7ity flo.
an+5or <u,<e+ flo. +e<en+ing on the <re7ailing en7iron,ental con+itions* I,<le,entation
! Re,o7al of sus<en+e+ soli+s -efore the effluent enters the <i<eline is one of the -est o<tion to i,<ro7e ser7ice ti,e
of the <i<eline* This shall also re+uce the ,aintenance <ro-le,s? such as clogging? an+ ,anhole o7erflo. along the
<i<eline*
0 The initial secure+ lan+fill ,ay get fille+ o7er a <erio+ of ti,e* Therefore? it ,ay -e necessary to construct
a++itional secure+ lan+fills as <er re;uire,ent* The ,ost i,<ortant as<ect of a <lace for secure+ lan+fill is that it
shoul+ lie relati7ely at a higher ele7ation so that +uring rainy season no floo+ing occurs* 3urther? <ro7ision shoul+
-e gi7en for trans<ort of see<age fro, the secure+ lan+fill to the e;uali:ation tan=* There are se7eral re;uire,ents
for a hazard waste management facility as +efine+ -y the Central Pollution Control 8oar+? Ne. Delhi? an+?
therefore? the selection of a <lace for secure+ lan+ fill an+ its +esign shoul+ ,eet these criteria* $s far as <ossi-le?
secure+ lan+fills shoul+ -e near-y the co,,on effluent treat,ent facility so that see<age han+ling ,ay -e ,a+e
easy* It is also essential to allocate a larger area for secure+ lan+fill to ,eet future +e,an+s*
) $s far as <ossi-le? the C#TP location shoul+ -e a.ay fro, ur-an <o<ulation to ,ini,i:e or? nullify the
en7iron,ental i,<act u<on the,*
/ $rchaeological treasures an+ their <ro9i,ity is one of the factor consi+ere+ .hile gi7ing the consent for the
esta-lish,ent of a C#TP*
#CP CONS"TIN4 Page>0 ...*ec<consulting*in
of gra7ity flo. is one of the o<tions that shall re+uce energy +e,an+ I there-y <a7ing .ay
for re+uce+ o<erating cost <er litre of effluent to -e treate+*
3. PROPOSED TREATMENT SCHEMES
Once effluent reaches the C#TP? it has to -e store+? e;uali:e+? an+ ,a+e suita-le for further
treat,ent* There are se7eral o<tions a7aila-le for treating the effluent* The effluent ,ay -e a
co,-ine+ one I ,eaning that a ,i9ture of +ye -ath? .ash .ater? <rinting? an+ -leaching effluent* It
,ay also -e segregate+* Je shall consi+er the <ros an+ cons of each of these ,etho+s in -rief here*
3.1 TREATING SEGGREGATED AND COMBINED RAW EFFLUENT
Segregation essentially ,eans se<arating effluent -ase+ on their generation <rocess I such as
+yeing? -leaching? <rinting? etc. The a+7antages an+ +isa+7antages are +iscusse+ here in -riefA
1* The ,ain a+7antage here is that +e<en+ing on the nature of the effluent? necessary treat,ent
is gi7en only to the ;uantity of effluent generate+ in that <articular <rocess* 3or e9a,<le? if
+ye -ath is segregate+? since its 7olu,e is lo. co,<are+ to the .ash .ater an+ its total
+issol7e+ soli+s CTDSD content is higher? it can -e +irectly e7a<orate+ .ith an e7a<oratorG if
+ye -ath is co,-ine+ .ith .ash .ater? then it is necessary to han+le the .hole 7olu,e
+o.n through all re;uire+ treat,ent <rocesses*
2* Due to segregation? each ty<e of effluent has to -e store+ in se<arate tan=s at each ,e,-er
units? an+ each of the, ha7e to -e <asse+ through a se<arate <i<eline to the C#TP*
#,<loy,ent of se<arate <u,<s ,ay also -e necessary* This is? ,ost of the ti,e? an
e9<ensi7e an+ a.=.ar+ o<tion*
!* De<en+ing on the nature of the segregate+ effluent? e,<loy,ent of +ifferent unit <rocesses
an+ e;ui<,ents ,ay -e necessary* #,<loy,ent of se<arate treat,ent units for each ty<e of
effluent shall result in higher ca<ital in7est,ent that shall re+uce the financial feasi-ility of
the <ro@ect* Due to increase+ ,aintenance loa+? this shall also increase o<erating costs*
0* $s the te,<erature of the +ye -ath is aroun+ H0>80C? it shall ta=e ,ore ti,e for natural
cooling .hen co,<are+ .ith co,-ine+ ra. effluent* Thus? in or+er to <ro7i+e ,ore ti,e? a
storage tan= .ith larger +etention ti,e ,ay -e re;uire+* Or? force+ cooling has to -e
i,<le,ente+* This is an a++itional cost to the total <ro@ect* If .ash .ater is allo.e+ to ,i9
.ith the +ye -ath? the te,<erature of the co,-ine+ ra. effluent shall ha7e alrea+y -een
lo.ere+ since the te,<erature of the .ash .ater utili:e+ for .ashing <ur<ose is al.ays at
a,-ient*
)* In the case of segregation? there is no .ay of re+ucing the organics loa+ing of the effluent*
Therefore? the con+ensate fro, the e7a<orator ,ay contain high le7els of 7olatile organic
car-on C%OCD co,<oun+s* Presence of these co,<oun+s in the reco7ere+ .ater shall <ose
<ro-le,s in +yeing such as un+esire+ tint* In the case of co,-ine+ ra. effluent? ,ost of the
organics in the effluent shall -e e9hauste+ -y ,icro-es +uring aero-ic5anaero-ic o9i+ation*
$lso? recalcitrant organics shall fin+ their .ay into slu+ge -y a+o<ting suita-le unit
<rocesses* Thus? the organics content of the reco7ere+ .ater utili:ing co,-ine+ ra. effluent
shall -e co,<arati7ely lo.er*
/* Jhen +ye -ath is +irectly treate+ .ith an e7a<orator? the <ro-le, of colour re,o7al has to
-e <ro<erly a++resse+* Nor,ally? chlorine is utili:e+ for this <ur<ose* Since chlorine for,s
chloro>organic co,<oun+s? .hich are carcinogenic e7en at the <arts <er ,illion le7el? it
shall ha7e un+esira-le effect on the en7iron,ent* 8oth chlorine an+ o:one Cthe other o<tion
#CP CONS"TIN4 Page>) ...*ec<consulting*in
for colour re,o7alD are highly corrosi7e* Therefore? traces of the, ha7e to -e re,o7e+
-efore the effluent reaches the e7a<orator* This is an a++itional cost* 3urther? chlorine5o:one
<ro+uction an+ han+ling is <ro-le,atic an+ re;uires s<ecial s=ills* $cci+ental release of
-oth of these gases shall <ose se7ere health ris=s*
The only +isa+7antage .ith han+ling co,-ine+ ra. effluent is that a large 7olu,e has to -e
han+le+* (o.e7er? consi+ering the -enefits? it is al.ays +esira-le to treat co,-ine+ ra. effluent
instea+ of engaging segregation*
3.2 PRIMARY TREATMENT SYSTEM
The ,ain o-@ecti7es of <ri,ary treat,ent syste, areA
1* Re,o7al of sus<en+e+ soli+s is an i,<ortant as<ect of <ri,ary treat,ent* Sus<en+e+ soli+s
+oes not nee+ any treat,ent other than their total re,o7al* Since sus<en+e+ soli+s ,ay or
,ay not che,ically react .ith the effluent? their total re,o7al ,ay also -enefit through
re+uce+ che,ical consu,<tion I if they react .ith a++e+ treat,ent che,icals*
2* $chie7ing flo. e;uali:ation? there-y ena-ling uninterru<te+ su<<ly of effluent to the
treat,ent units* It shoul+ -e note+ that if the <ur<ose of e;uali:ation is only to achie7e flo.
e;uali:ation? it is a <oor +esign* #;uali:ation <rocess shoul+ also a++ress the <ro-le, of
ho,ogeni:ation of the influent so that 7aria-ility in effluent characteristics are greatly
,ini,i:e+* This <a7es .ay for +esigning a syste, .ith clear u<<er an+ lo.er o<erating
li,its an+ assist in the ,aintenance of goo+ <erfor,ance
H
*
!* $+@ust,ent of <( to neutral is another i,<ortant as<ect of <ri,ary treat,ent* Nor,ally? <(
correction is ,a+e after e;uali:ation .ith the ai+ of a flash ,i9er an+ then the effluent
<asses to the ne9t treat,ent unit* Jhereas? it is al.ays -eneficial to carry out <( correction
at the e;uali:ation tan= itself* There are certain -enefits associate+ .ith this as<ect* One of
the, is that +ue to higher +etention ti,e a7aila-le in the e;uali:ation tan= > co,<are+ to
inline aci+ +osing
8
for <( a+@ust,ent I the 7aria-ility in <( is largely controlle+* 3urther?
enough ti,e is gi7en for neutrali:ation so that all che,ical reactions resulting fro, the
a++ition of aci+ are essentially co,<lete+* 3urther? all car-onates in the influent I e7en
slo.ly reacting one > are -rought into solution -y aci+ification at the e;uali:ation tan=* $ny
further <( a+@ust,ent to the effluent fro, e;uali:ation tan= shoul+ -e carrie+ out in a flash
,i9er*
0* Oil an+ grease re,o7al is one of the i,<ortant as<ect in the +esign of a <ri,ary treat,ent
syste,* Nor,ally oil s=i,,er is utili:e+ for this <ur<ose* $lso? re,o7al of free chlorine
1
is
7ery ,uch essential I since <resence of free chlorine in the effluent shall +a,age the re7erse
os,osis ,e,-ranes*
)* $fter <( a+@ust,ent? the effluent shoul+ -e treate+ -y any one of the follo.ing +esire+
<rocesses to achie7e re+uction in -iological o9ygen +e,an+ C8ODD an+ che,ical o9ygen
+e,an+ CCODD* So,e of the a7aila-le o<tions areA iD si,<le aerationG iiD acti7ate+ slu+ge
H #;uali:ation is an i,<ortant <rocess that +eci+es the <erfor,ance of the syste, +o.n the line* Often? +esign of
<ro<er e;uali:ation syste, is i,<ro<er +ue to the un+erstan+ing that it nee+s only to e;uali:e the flo.* 8ut the fact
re,ains that a goo+ e;uali:ation <rocess shoul+ also a++ress the <ro-le, of ho,ogeni:ation an+ ,aintaining? as far
as <ossi-le? a constant loa+ing rate of +esire+ effluent constituents* So,e of the -est <ractices in the +esign of
e;uali:ation <rocess are consi+ere+ in the article Achieving Zero Discharge in ndustrial !aste !ater Treatment
Plants .hich is a7aila-le for +o.nloa+ fro, ...*ec<consulting*in
8 Te9tile .aste .ater <( is al.ays in al=aline range* (ence? neutrali:ation is +one using aci+*
1 The co,-ine+ ra. effluent ,ay contain higher le7els of free chlorine if it has -leaching effluent as one of its
co,<onents* (o.e7er? -y utili:ing <ero9i+e -leaching? it is <ossi-le to generate effluent free fro, free chlorine* $ll
,e,-er units ha7e to ,a=e an agree,ent .ith regar+ to the -leaching <rocess to -e e,<loye+*
#CP CONS"TIN4 Page>/ ...*ec<consulting*in
<rocess .ith5.ithout aeration Cthis inclu+es S8R an+ $S8 <rocessesDG iiiD aero-ic5
anaero-ic +igestion .ith flu+i:e+ -e+ -ioreactor C388RDG i7D use of a ,e,-rane -ioreactor
C'8RD* Selection of any one of these <rocesses for <ri,ary treat,ent of effluent for the
re+uction of 8OD5COD largely +e<en+s on the a7aila-le financial an+ other resources Csuch
as lan+D an+ +esire+ le7el of <erfor,ance* These are +escri-e+ -riefly in the follo.ing
<aragra<hs*
CaD During si,<le aeration? su<<ly of air is continuously ,aintaine+ an+ that su<<lies
re;uire+ ;uantity of o9ygen for the gro.th of ,icro-ial <o<ulation* The organics in the
effluent are consu,e+ -y aero-ic -acteria an+ results in 8OD5COD re+uction* n+er
this <rocess? the soli+s retention ti,e CSRTD is e;ual to hy+raulic retention ti,e C(RTD*
Pro7ision of enough +etention ti,e is essential for running a si,<le aeration syste,G
other.ise? 8OD5COD re+uction shall -e less*
C-D n+er acti7ate+ slu+ge <rocess? aeration stage is follo.e+ -y a settler .here the
se<aration of sus<en+e+ soli+s is achie7e+* The settle+ soli+s contain acti7e ,icro-es
that are returne+ to the aeration tan=* 8y recirculating the sus<en+e+ soli+s? the soli+s
retention ti,e CSRTD is enhance+? there-y <ro,oting the +egra+ation of organics* The
acti7ate+ slu+ge <rocess ,ay either -e an aero-ic <rocess? an ano9ic <rocess or? a hy-ri+
<rocess .here aero-ic an+ ano9ic con+itions are cycle+
10
* The selection of aero-ic or?
anaero-ic <rocess largely +e<en+s on the nature of the effluent* The ,ain a+7antage of
e,<loying acti7ate+ slu+ge <rocess is that it re;uires co,<arati7ely less aeration tan=
7olu,e? less +etention ti,e? an+ o<erates un+er high ,i9e+ li;uor sus<en+e+ soli+s
C'"SSD concentration co,<are+ to si,<le aeration* $+o<tion of this ,etho+ ena-les
re+uction of shoc= loa+s* <flo. $naero-ic Slu+ge 8lan=et C$S8D reactor e,<loys
anaero-ic +igestion un+er acti7ate+ slu+ge <rocess .hile? Se;uential 8atch Rector
CS8RD utili:es -oth aero-ic an+ ano9ic <rocesses
11
* sing S$8 it is <ossi-le to
generate -iogas fro, the .aste .ater an+ generate electricity
12
* The S8R <rocess is 7ery
,uch useful in achie7ing nitrate re,o7al
1!
*
CcD Jhile si,<le aeration an+ acti7ate+ slu+ge <rocesses +iscusse+ a-o7e e,<loys
sus<en+e+ gro.th =inetics? e,<loy,ent of 388R utili:es attache+ gro.th =inetics* The
,ain a+7antage of e,<loying 388R are ,any* So,e of the, areA
iD higher retention of sus<en+e+ -io,ass?
iiD <rolonge+ soli+s retention ti,e CSRTD to ena-le co,<lete ,icro-ial +egra+ation of
slo.ly +egra+ing organics?
iiiD re+uction in shoc= loa+s? an+
i7D high ;uality effluent lo. in 8OD5COD*
C+D se of '8R for te9tile .aste .ater treat,ent is one of the -est a7aila-le o<tions* It
re+uces the foot <rint? i,<ro7es 8OD5COD re+uction? eli,inates the nee+ for a
secon+ary clarifier? re,o7es sus<en+e+ soli+s? gi7es unifor, out<ut of effluent? can -e
10 The +esire+ +uration of the cycle +e<en+s on the intensity of nitrification an+ +enitrification*
11 In S8R? aeration is s.itche+ on +uring fill an+ react <erio+s* During fill <erio+ .aste .ater is <u,<e+ into S8RG
react <erio+ is the ti,e in .hich ,icro-ial reaction .ith .aste .ater constituents is allo.e+ to ha<<en* This is
follo.e+ -y a "uiescent <erio+ .hen sus<en+e+ soli+s are allo.e+ to settle* Then? the su<ernatant is +ecante+ an+
settle+ slu+ge that contains ,icro-es is recycle+ in the sa,e S8R tan=* During aeration? N(
0
>N is o9i+i:e+ to NO
!
*
12 se of $S8 <rocess also re+uces the ;uantity of slu+ge generate+* (o.e7er? SRT shoul+ -e ,aintaine+ high
enough to achie7e +esire+ results*
1! 3or +enitrification to -e effecti7e? the s.itch>off <erio+ shoul+ -e <rolonge+ to ,aintain ano9ic .ater colu,n for a
sufficient <erio+*
#CP CONS"TIN4 Page>H ...*ec<consulting*in
o<erate+ at higher '"SS concentration? an+ re+uces shoc=s
10
* (o.e7er? the ca<ital
in7est,ent associate+ .ith the esta-lish,ent of a '8R syste, is higher than other
syste,s*
/* The ne9t ste< in <ri,ary treat,ent is colour an+ tur-i+ity re,o7al* It shoul+ -e re,e,-ere+
here that colour re,o7al shoul+ -e effecte+ only after 8OD5COD re+uction* Other.ise? the
loa+ on the unit <rocess that re,o7es the colour shall -e hea7y an+ it ,ay not -e <ossi-le to
achie7e +esire+ out<ut* 3or colour re,o7al the follo.ing unit <rocesses can -e a+o<te+A iD
chlorination? iiD o:onation? iiiD e,<loy,ent of acti7ate+ car-on filter*
CaD Of these three ,etho+s? chlorination is not consi+ere+ en7iron,ent frien+ly an+ its
a<<lication in .aste .ater treat,ent is .i+ely +is<ute+*
C-D O:onation ,ay -e carrie+ out alone or? it ,ay -e co,-ine+ .ith % irra+iation* %>
O:onation is a highly efficient <rocess .hen co,<are+ .ith si,<le o:onation* Since
o:one is a highly o9i+i:ing agent? colour re,o7al is easily achie7e+* So,e other +esire+
out<ut o-taine+ +ue to the a<<lication of o:one is that it o9i+i:es +issol7e+ iron in the
.aste .ater to colloi+al iron hy+ro9i+e* Due to this the .aste .ater turns tur-i+* Since
iron hy+ro9i+e a+sor-s ,ost of the trace ,etals in the .aste .ater? -y <ro<er filtration
Cfor e9a,<le? using a <ressure san+ filterD? -oth +issol7e+ iron an+ other trace ele,ents
are re,o7e+* Re,o7al of +issol7e+ iron is ,ost critical since it is to9ic to the re7erse
os,osis ,e,-ranes use+ in secon+ary treat,ent for .ater reco7ery*
CcD Jhen the re;uire+ le7el of colour re,o7al is less? e,<loy,ent of acti7ate+ car-on filter
can also -e consi+ere+* $cti7ate+ car-on filter re,o7es traces of free chlorine? organics?
an+ ,any trace ele,ents <resent in the .aste .ater* Due to its granular for,? it also
re,o7es a <art of sus<en+e+ soli+s* The ,ain <ro-le, .ith the e,<loy,ent of acti7ate+
car-on filter is that it has to -e rene.e+ often*
C+D Tur-i+ity re,o7al is also achie7e+ -y e,<loying PS3 an+ $C3*
3.3 SECONDARY TREATMENT SYSTEM
Once sus<en+e+ soli+s are re,o7e+? 8OD5COD re+uction is achie7e+? tur-i+ity an+ colour are
re,o7e+? the .ater has to -e su-@ecte+ to secon+ary treat,ent for the reco7ery of .ater* There are
se7eral as<ects that shoul+ -e consi+ere+ in the +esign of a secon+ary treat,ent syste,*
1* The secon+ary treat,ent syste,? that nor,ally e,<loys re7erse os,osis ,e,-ranes? shoul+
-e a-le to o<erate .ith the +esire+ TDS le7el ty<ical of the effluent* It shoul+ also generate
<er,eate .ith acce<ta-le ;uality*
2* It shoul+ -e a-le to .ithstan+ ,e,-rane scaling cause+ -y 7arious constituents in the
effluent* 8iofouling is another <ro-le, that has to -e suita-ly controlle+*
!* To achie7e ,a9i,u, -enefits? the <ercentage of reco7ery of <ure .ater shall -e ,aintaine+
at higher si+e* (o.e7er? increase+ reco7ery also re;uire higher o<erating <ressure an+ also
results in fre;uent fouling of the ,e,-rane* Therefore? it is essential to utili:e highly
o<ti,i:e+ syste, in <lace*
0* 8y ,onitoring the re7erse os,osis fee+ ;uality .ith suita-le sensors? auto,ate+ -ac=.ash
an+ +i7ersion of effluent .ith un+esira-le ;uality
1)
to a se<arate tan= can -e achie7e+* These
10 Re+uction in shoc=s is essentially +ue to recirculation of effluent fro, the ,e,-rane co,<art,ent to that of ano9ic
:one an+ ,aintenance of higher le7els of '"SS Ca-out 10?000 to 20?000 ,g5"D* $ ,ore +etaile+ +iscussion a-out
a<<lication of ,e,-rane -ioreactor for te9tile .aste .ater treat,ent is a7aila-le in the article Te#tile !astewater
Treatment with $em%rane &ioreactor a7aila-le for +o.nloa+ fro, ...*ec<consulting*in
#CP CONS"TIN4 Page>8 ...*ec<consulting*in
,easures are essential for the <rotection of the ,e,-rane syste, .hich shall increase its
life ti,e*
)* There shall al.ays -e <erfor,ance +egra+ation of the ,e,-rane syste, that re+uces the
;uantity of <er,eate that can -e o-taine+* 3urther? .ith ti,e? the salt <assage through the
,e,-rane increases? resulting in higher TDS <er,eate* In a++ition to these issues?
-ac=.ash o<erations re+uces total functional ti,e of the ,e,-rane syste,* $s the
-ac=.ash fre;uency +e<en+s ,ainly on the fouling <otential of the effluent an+ the
o<erating con+itions of the re7erse os,osis syste,? the +o.nti,e Ci.e.? off>line <erio+D of
the ,e,-rane syste, ,ay 7ary fro, ti,e to ti,e* Therefore? it is essential to +esign the
,e,-rane syste, .ith a significant ,argin*
/* In or+er to re+uce ,e,-rane fouling an+ -ac=.ash fre;uency? fouling resistant ,e,-ranes
,ay -e utili:e+*
H* The re7erse os,osis syste, has to i,<le,ent stages
'(
an+5or passes
')
to o-tain higher
<ercentage of reco7ery an+ <er,eate of +esire+ ;uality* 'i9ing +esire+ ;uantity of <er,eate
.ith the fee+ an+ recirculating it through the ,e,-rane syste, is another o<tion to ,aintain
syste, <erfor,ance* $ll these things shall -e consi+ere+ +uring +esign <hase of the
,e,-rane syste,*
3.4 TERTIRARY TREATMENT SYTEM
The <ri,e o-@ecti7e of a tertiary treat,ent syste, is to treat the re@ect generate+ -y the re7erse
os,osis syste,* Nor,ally the tertiary syste, e,<loys an e7a<orator that utili:es stea, as heating
source? <ro+uces reusa-le .ater in the for, of con+ensate? an+ generates -lo. +o.n an+ salt as -y
<ro+ucts*
1* The ,ain <ro-le, face+ in an e7a<orator is scaling* 3or goo+ ,aintenance? an e7a<orator
has to -e cleane+ +aily*
2* Jhen so+iu, sul<hate is utili:e+ in +yeing <rocess? the salt is reco7ere+ in the e7a<orator I
an+ that re,ains reusa-le* (o.e7er? if so+iu, chlori+e is utili:e+ in the +yeing <rocess?
then the reco7ere+ salt contains higher le7el of i,<urities I ,a=ing it unsuita-le for reuse*
(o.e7er? it is still <ossi-le to <urify the salt an+ ,a=e it reusa-le* The .ays of achie7ing
this shoul+ -e e9<lore+* If this is not achie7a-le then? the +esign of secure+ lan+fill shoul+
ta=e into account +is<osal of the salt reco7ere+ fro, the e7a<orator*
!* The e7a<orator +esign shoul+ consi+er utili:ation of .aste heat fro, the stea,* Co>
generation is another o<tion that has to -e consi+ere+ fro, right in the -eginning*
0* The -lo. +o.n fro, e7a<orator has to -e treate+ .ith a solar e7a<oration <on+* In or+er to
enhance e7a<oration rate? i,<le,entation of force+ e7a<oration ,etho+s? such a
construction of a s<ray <on+? ,ay -e consi+ere+*
1) 3or e9a,<le? -y ,onitoring the o9i+ation>re+uction <otential CORPD? <resence of highly o9i+ising su-stances in the
effluent? such as free chlorine? can -e ,onitore+* $uto,ate+ -ye <assing of this effluent to another tan= re+uces the
chances of ,e,-rane +a,age* Si,ilarly? sensors ,ay -e fi9e+ for the ,easure,ent of TDS an+ <( of re7erse
os,osis fee+G the syste, ,ay -e auto,ate+ to han+le these issues in a +esira-le .ay*
1/ If the re@ect fro, a ,e,-rane ,o+ule is treate+ -y another ,o+ule? then this configuration is calle+ stage*
Nor,ally? +ual stage ,e,-rane syste,s are e,<loye+ in te9tile .aste .ater treat,ent*
1H If <er,eate fro, a ,e,-rane ,o+ule is treate+ -y another ,o+ule? then this configuration is =no.n as <ass* This is
,ainly utili:e+ to re+uce the TDS of the <er,eate*
#CP CONS"TIN4 Page>1 ...*ec<consulting*in
4 OPTIMIZATION OF SYSTEM DESIGN AND PERFORMANCE
The success or failure of a .aste .ater treat,ent facility in achie7ing :ero +ischarge largely
+e<en+s on ho. ,uch o<ti,i:ation is achie7e+ in the +esign <hase of the full>scale <lant* Jhen a
.aste .ater treat,ent syste, is esta-lishe+? it is nor,ally thought that the syste, has to <erfor, to
the +esire+ le7el since it is +esigne+ so* (o.e7er? a lot of things are left in the +esign <hase* So,e
of the, are +iscusse+ -elo.*
1* Ste<s for o<ti,i:ation shoul+ start right fro, <ilot <lant tests* The =inetic <ara,eters
o-taine+ fro, <ilot <lant for the chosen treat,ent syste, shoul+ -e e,<loye+ for full>scale
<lant +esign* $llo.ance shoul+ -e gi7en in si:ing the units -y ta=ing into consi+eration the
7aria-ility of effluent <ara,eters? an+ the e9<ecte+ 7aria-ility in the <erfor,ance of each
treat,ent unit* The syste, +esign shoul+ also consi+er nor,al off>line <erio+ of rele7ant
treat,ent unit
18
? an+ interru<tions +ue to ,aintenance shoul+ -e consi+ere+* $ syste,
+esign that +oes not consi+er 7aria-ility in effluent characteristics shall <ose o<erational
<ro-le,s at later stages? finally resulting in failure to achie7e +esire+ results*
2* The <erfor,ance of each treat,ent unit ,ay 7ary fro, ti,e to ti,e +e<en+ing on fee+
;uality* 3or e9a,<le? the su-strate utili:ation rate in the aeration syste, increases
e9<onentially .ith su-strate concentration* If the syste, is <ro<erly +esigne+? any increase
in fee+ su-strate concentration shall -e s,oothe+ out -y increase+ su-strate utili:ation rate I
there-y re+ucing occurrence of shoc=s in the treate+ effluent* This shall i,<ro7e
<erfor,ance of the treat,ent syste, an+ re+uce syste, u<>sets*
!* The syste, <erfor,ance ,ay also +ecline .ith ti,e +ue to continue+ o<eration an+ ageing*
Jhile cleaning of the treat,ent unit tries to restore the <erfor,ance of a treat,ent unit? it
,ay not -e 100K effecti7e* Thus? <ro<er allo.ance shoul+ -e gi7en in si:ing each treat,ent
unit -y consi+ering the e9<ecte+ life>ti,e of the treat,ent unit an+ its a7erage <erfor,ance
+ecline o7er the <erio+ in ser7ice*
0* Since aeration is an energy intensi7e <rocess an+ consu,es aroun+ 20>!0K of total electric
<o.er re;uire+ in a .aste .ater treat,ent <lant? -y o<ti,i:ing the aeration syste, it is
<ossi-le to re+uce o<erating costs* Con+ucting o9ygen transfer efficiency COT#D tests is an
essential <art of o<ti,i:ing the aeration syste,* The actual o9ygen re;uire,ent ,ay 7ary
fro, ti,e to ti,e an+ the aeration syste, shoul+ -e a-le to a+@ust itself to <re7ailing
con+itions*
)* Due to co,<le9 nature of the su-strates? the o9ygen u<ta=e rate follo.s a ste<>li=e cur7e*
This can -e o-ser7e+ -y la-oratory e9<eri,ents* The syste, +esign shoul+ consi+er this fact
fro, right in the -eginning an+ the hy+raulic resi+ence ti,e C(RTD of the effluent at the
aeration tan= shoul+ -e greater than the ti,e re;uire+ for attaining a ,ini,u, o9ygen
u<ta=e rate*
/* The syste, +esign shoul+ consi+er the effect of te,<erature on ,icro-ial gro.th an+ its
=inetics* Since ,icro-ial gro.th rate +ecreases .ith te,<erature? the syste, +esign shoul+
-e a-le to a-sor- this*
18 Pressure San+ 3ilter CPS3D an+ $cti7ate+ Car-on 3ilter C$C3D shall -e in off>line ,o+e .hen -ac=.ash o<eration is
carrie+ out* Si,ilarly? re7erse os,osis syste, shall -e in off>line ,o+e +uring <erio+s .hen fee+ ;uality e9cee+s the
+esire+ li,its as .ell as +uring the <erio+s of -ac=.ash* #7a<orator shall -e off>line .hen cleaning o<eration is
con+ucte+* The .hole syste, shall -e in off>line ,o+e .hen syste, u<>sets are o-ser7e+* Pro<er allo.ance shoul+
-e gi7en in treat,ent ca<acity? hours of treat,ent
#CP CONS"TIN4 Page>10 ...*ec<consulting*in
H* Occurrence of short*circuiting
'+
in each tan=s shoul+ -e stu+ie+ -efore co,,issioning the
full>scale <lant* Necessary re,e+ial ,easures shoul+ -e i,<le,ente+*
8* Settling is one of the i,<ortant <rocesses e,<loye+ in any .aste .ater treat,ent facility
20
*
The <erfor,ance of settling tan= largely +e<en+s on overflow rate
,'
an+ the nature of the
effluent* The settlea-ility of slu+ge
22
shall also affect the soli+s retention -y the settling tan=*
The o7erflo. rate not only +eter,ines the <ercentage of re,o7al of sus<en+e+ soli+s I -ut
also 8OD5COD re+uction associate+ .ith <articulate re,o7al* In a <ro<erly +esigne+
syste,? at any <oint in ti,e the total sus<en+e+ soli+s CTSSD re,o7al shoul+ fall .ithin
+esire+ li,its* $ccor+ingly? the 8OD5COD re,o7al efficiency shoul+ also -e stu+ie+*
1* The syste, shoul+ al.ays -e +esigne+ to treat all the effluent generate+ in a +ay .ithin 18
hours? =ee<ing the re,aining / hours to account for <erfor,ance +egra+ation? carrying out
regular ,aintenance .or=s? ,eeting une9<ecte+ interru<tions? etc. This as<ect is essential in
any :ero +ischarge treat,ent facility*
10* The syste, shoul+ al.ays -e run -elo. the rate+ full ca<acity to ensure that the syste, is
not throttle+ at any ,o,ent* This shall ensure ,aintenance of goo+ <erfor,ance of all
treat,ent units o7er their life <erio+*
5 RESOURCES NEEDED/REQUIREMENTS
The follo.ing technical re;uire,ents ha7e to -e ,et in or+er to esta-lish a :ero +ischarge syste,*
1* $ssess,ent of e9isting treat,ent technologies for te9tile .aste .ater treat,ent is a first
technical re;uire,ent* 8ase+ on a7aila-le infor,ation? a treat,ent syste, has to -e chosen*
2* The chosen treat,ent syste, iD shoul+ -e a-le to <ro+uce effluent .ith +esire+ ;uality? an+
iiD it shoul+ not <ro+uce any har,ful su-stances on its o.n*
!* In or+er to assess the 7ia-ility of a<<lying the selecte+ treat,ent syste,? it is necessary an+
essential to con+uct <ilot <lant test runs* It shoul+ -e note+ here that any :ero +ischarge
i,<le,entation .ith out a soli+ -ac= u< fro, <ilot <lant test run +ata is su-@ecte+ to failure*
The <ilot <lant not only <ro7i+es the ,eans of assessing the 7ia-ility of technology I it also
<ro7i+es enough +ata for the +esign of a full>scale syste,* 3urther? any <ro-le,s that ,ay
arise in a full>scale i,<le,entation can -e i+entifie+*
0* The full>scale +esign shoul+ only -e -ase+ on the co,-ine+ effluent characteristics of all
,e,-er units* Ta=ing into consi+eration the 7aria-ility in each <ara,eter is 7ery ,uch
essential* The treat,ent syste, +esign shoul+ -e a-le to .ithstan+ at the least 11K of
statistically significant 7aria-ility in effluent <ara,eters* Other.ise? the <erfor,ance of the
11 -hort*circuiting is a <heno,enon .here the influent esca<es <ro<er treat,ent -y e9iting the treat,ent unit -efore
the +esire+ +etention ti,e* The occurrence of this <heno,enon is largely +ue to geo,etry of the tan=? flo. regi,e?
<lace,ent of inlet an+ outlet? etc. $ +esign that +oes not consi+er occurrence of short*circuiting is su-@ecte+ to
failure*
20 In .aste .ater treat,ent syste,s e,<loying ,e,-rane -ioreactor C'8RD? settling is not necessary as soli+s
se<aration fro, li;ui+ is acco,<lishe+ -y the ,e,-ranes* Therefore? <ro-le,s associate+ .ith slu+ge settlea-ility
is also o7erco,e using a '8R*
21 This is +efine+ as the ratio of total 7olu,e of the tan=5surface area of o7erflo.*
22 This? in turn? is affecte+ -y foo+5,icroorganis,s C35'D ratio that is ,aintaine+ in the aeration tan=* O<erating the
<lant .ith lo. 35' ratio ensures goo+ settlea-ility of the slu+ge an+ -etter 8OD5COD re,o7al* "o.ering this ratio
re;uires ,aintenance of high '"SS concentration? .hich is <ossi-le only .ith the a+o<tion of acti7ate+ slu+ge
<rocess or? a ,e,-rane -ioreactor C'8RD syste,*
#CP CONS"TIN4 Page>11 ...*ec<consulting*in
treat,ent syste, shall -e greatly affecte+
2!
* It is also +esira-le to ha7e so,e ,argin in the
+esign li,its to account for future <erfor,ance +egra+ation*
)* Pi<eline +esign for effluent trans<ort an+ return of treate+ effluent to the ,e,-er units fro,
the C#TP is one of the i,<ortant as<ect of i,<le,enting a :ero +ischarge syste,* This has
alrea+y -een +iscusse+ un+er S ection>2*
/* The <rocesses that generate the effluent are to -e i+entifie+ at first* "isting out all che,icals
an+ their ;uantities utili:e+ in te9tile .et <rocessing is also i,<ortant* This gi7es necessary
infor,ation a-out the characteristics of the effluent that is generate+ in te9tile .et
<rocessing* Only then it ,ay -e <ossi-le to =no. the list of <hysical an+ che,ical
characteristics that nee+ to -e analyse+ in the effluent* This hel<s in selecting suita-le
treat,ent units*
H* "isting all energy conser7ing ,easures are 7ery ,uch essential to re+uce o<erating costs*
So,e of these ,easures inclu+e e,<loy,ent of energy reco7ery +e7ice in the re7erse
os,osis syste,? .aste heat reco7ery syste,s? e,<loy,ent of energy efficient ,otors an+
<u,<s? lighting? etc.
8* Con+ucting le7elling sur7ey is 7ery ,uch essential to +esign the <i<eline I -oth for
i,<le,enting gra7ity flo. as .ell as for <u,<e+ flo.* Collection of infor,ation a-out total
nu,-er of ,e,-er units? each oneLs locality? <resent an+ future +ischarge ca<acity? the
nu,-er an+ si:e of a7aila-le storage tan=s for te,<orary storage of effluent at each ,e,-er
unit? an+ any other relate+ infor,ation is 7ery ,uch essential for the +esign of a goo+
collection an+ con7eyance syste,* $ <oorly +esigne+ collection an+ con7eyance syste,
shall al.ays -ring ha7oc to the C#TP as .ell as to the ,e,-er units* The +esign shoul+ also
inclu+e <articulars a-out the <lace,ent of air>loc=5<ressure release 7al7es? ,anholes?
collection su,<s? an+ flo. ,eters
20
1* The syste, shoul+ consi+er .ays of han+ling un+esira-le situations such as iD fee+ .ith
un+esira-le ;uality? iiD <o.er failure? iiiD <erio+s of ,aintenance? an+ i7D floo+ing*
6 UNIT PROCESSES
The a<<lica-ility an+ use of 7arious technologies for te9tile .aste .ater treat,ent is alrea+y
+escri-e+* Of all these ,etho+s? using '8R <rocess for <ri,ary treat,ent is the -est o<tion*
(o.e7er? it is co,<ara-ly costlier than other ,etho+s* Other reco,,en+e+ ,etho+s are S8R an+
$S8 <rocesses* Irres<ecti7e of the technology to -e a+o<te+? follo.ing unit <rocesses are
necessary for the treat,ent of the te9tile .aste .ater to achie7e :ero +ischarge*
1* Re,o7al of grits an+ sus<en+e+ soli+s
2* Re,o7al of oil & grease
!* #;uali:ation
0* $+@ust,ent of <(
)* Re+uction of 8OD5COD
2)
/* Re,o7al of colour
2! Refer Performance .ptimization of !aste !ater Treatment Plants for a +etaile+ +iscussion on i,<ro7ing
<erfor,ance of .aste .ater treat,ent <lants* This +ocu,ent is a7aila-le for +o.nloa+ fro, ...*ec<consulting*in
20 It is 7ery ,uch essential to ha7e $uto,ate+ 'eter Rea+ing C$'RD i,<le,entation so that any lea=age or -rea=>u<
along the <i<eline can -e i,,e+iately +etecte+ an+ necessary <re7enti7e ,easures can -e ta=en in ti,e* It also hel<s
in accounting effluent flo. an+ returne+ .ater su<<ly fro, an+ to the C#TP* 3urther to this? continuously
,onitoring the <ressure insi+e the <i<eline is 7ery ,uch essential in <re7enti7e ,aintenance*
#CP CONS"TIN4 Page>12 ...*ec<consulting*in
H* Reco7ery of reusa-le .ater
8* Treat,ent of re@ect Cfro, re7erse os,osis syste,5-lo. out fro, e7a<oratorD
1* Soli+ .aste +is<osal an+ ,anage,ent*
MMMMM NNNNN MMMMM
2) This can -e achie7e+ in se7eral .aysA iD si,<le aeration? iiD acti7ate+ slu+ge <rocess .ith aeration tan= an+ settling
tan= .ith a return line for su<<lying acti7e slu+ge? iiiD e,<loy,ent of $S8 reactor? 388R? S8R or? '8R? etc* The
,ain a+7antage of e,<loying $S8 reactor is that it can -e use+ to generate -iogas that ,ay -e use+ for <o.er
generation*
#CP CONS"TIN4 Page>1! ...*ec<consulting*in