Designing, Construction and Validation of Laboratory Type Textile Effluent Treatment Plant

Designing, Construction and Validation of Laboratory Type Textile Effluent Treatment Plant

Prepared by:
Mohammad Israfil Alam
Pre-registration no.: 1299 TTH ID: SEU-04 Department of Textile Engineering

SOUTHEAST UNIVERSITY
Mobile: +88 01717123339 Email: israfil_tex@yahoo.com

Supervisor:
Dr. Arun Kanti Guha
Assistant Professor Department of Textile Engineering

SOUTHEAST UNIVERSITY
Mobile: +88 01718833461 Email: arunguha70@yahoo.com

Approval
This is to Certify that Mr. Mohammad Israfil Alam has completed a study under my supervision entitled Designing, Construction and Validation of Laboratory Type Textile Effluent Treatment Plant to submit an assignment to the authority of Textile Talent Hunt Competition, 2010.

Table of Contents
Abstract ................................................................................................................................................. I 1. Introduction ................................................................................................................................... 1 1.1 1.2 1.3 2. 2.1 2.2 2.3 2.4 2.5 3. 3.1 3.2 Pollution by Textiles ............................................................................................................. 1 Characterization of Textile Wastewater of Different Areas of Bangladesh ...................... 3 Necessity of Laboratory Type Textile ETP ......................................................................... 4 List of costs of accessories .................................................................................................... 6 Plant Layout: Drawing Design ............................................................................................. 7 Plant Layout: Image ............................................................................................................. 8 Capacity of Different Tank ................................................................................................... 9 Devices Used in ETP Model...............................................................................................10 ETP Flow Chart .......................................................................................................................12 Treatment Processes ................................................................................................................13 Screening ..........................................................................................................................13 Equalization .....................................................................................................................13 Primary Clarifier: .............................................................................................................14 Oxidation ..........................................................................................................................15 Decoloring unit.................................................................................................................15 Secondary Clarifier ..........................................................................................................16 Sludge Processing Unit....................................................................................................16 Discharge ..........................................................................................................................16 Experiment Results: Sample 01 ......................................................................................17 Experiment Results: Sample 02 ......................................................................................18 Experiment Results: Sample 03 ......................................................................................19

Construction of Laboratory Type Textile ETP ........................................................................... 5

Experimental ...............................................................................................................................11

3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8 3.2.9 3.2.10 3.2.11 4. 5. 6. 7.

Results & Discussion ..................................................................................................................20 Conclusion ...................................................................................................................................23 Acknowledgements .....................................................................................................................24 References ...................................................................................................................................25

Abstract:
The rapid growth of textile industries creates environmental pollution, mainly water pollution. The reason of water pollution is lack of appropriate environmental management in textiles in Bangladesh .[1] Wastewater is the major environmental issue of the textile industries besides other minor issues like solid waste, residual waste etc. In Bangladesh most of the industrial units are located along the banks of the rivers and they do not use Effluent Treatment Plant (ETP) for wastewater. As a consequence, industrial units drain effluent directly into the rivers without consideration of the environment. Department of Environment (DoE) has visited 466 factories that produce harmful liquid wastes. Only 104 of them were found to have installed ETPs. However, only 56 ETPs were found to be in use by the owners. The rest of the ETPs were either closed to save operating cost or were out of order. Setup an effluent treatment plant is mandatory for a factory today. But due to its high construction cost many factories directly discharge effluent into the drain. In that case it is essential to know about textile wastewater management from the beginning of our engineering life. To this view point a laboratory type textile effluent treatment plant is constructed. We treat our laboratory wastewater in this ETP. Three samples were collected from dyeing laboratory. Before treatment pH was 11, 10, and 9 and after treatment pH is 7, 7 & 7 respectively. Before treatment color was deep blue, deep red & deep yellow and after treatment color is pale blue, pale red & pale yellow respectively. BOD, COD, TDS, TSS etc values could not be analyzed in laboratory due to unavailability of instruments. These tests required high cost and could not manage. This ETP model can be used as practical class for undergraduate textile students. The laboratory type ETP is essential in all laboratory of textile engineering department of all universities. This will help to know how to treat textile wastewater practically which is difficult to learn in factory.

1. Introduction:
In this industrialized age, environmental pollution is a matter of great concern. Surface water pollution is one of the elements of environmental pollution. Chemical processing industries especially textile processing industries are claimed to produce huge effluent to discharge in our rivers. A complex mixture of hazardous chemicals both organic and inorganic is discharged into the water bodies from all these industries, usually without treatment. It is well known that textile mills consume large volume of water for various processes such as sizing, desizing, scouring, bleaching, mercerizing, dyeing, printing, finishing and washing. Due to the nature of various chemical processing of textiles, large volume of wastewater with numerous pollutants are discharged everyday.

1.1 Pollution by Textiles:

Especially the chemical processing industries of textile like dyeing, printing, finishing & washing are mainly responsible for water pollution whereas the spinning, weaving, knitting, nonwoven, garment manufacturing etc have little or no contribution in water pollution. A flow chart of textile manufacturing:

Figure 1. Textile Manufacturing Processes[2]

Table1. Volume of Effluent produced by different processing of textiles .[2]

Amount of Effluent produced per day (m3)
1118 16,500 1,28,700 84,500 8500

Process Name
Weaving preparation Yarn dyeing Knit processing Woven processing Garment washing & dyeing

Production per Day

4.14 million meters/day 150 tones/day 1430 tones/day 3.84 million meters/day 500000 pcs/day

Department of Environment issues the Environmental Clearance Certificate to the various industries classified in categories of Green, Orange-A, Orange-B & Red in consideration of their site and impact on the environment. As per The Environment Conservation Rules 1997, number of categorized industries listed below:[2]

Factory

Category

Figure 02. A column diagram of a plot of factory Vs. category reported by DoE, Bangladesh.

Textile wet processes are logically in red category. They have strong rules of these types of industries including the preset up of Effluent Treatment Plant (ETP) plant in giving time period

to get the Environmental Clearance Certificate which is obvious to get utility connection like gas, water etc.

1.2 Characterization of Textile Wastewater of Different Areas of Bangladesh:[3]

We have to know pollution levels of different textile industrial zones. Textile wastewater collected from different areas are analyzed in laboratory and found high pH and Total Dissolved Solids (TDS) values in almost all areas. Maximum values of pH and TDS of different areas are given below in column diagrams.

Figure 3. A column diagram of maximum values of TDS (mg/L) of wastewater of different areas

Figure 4. A column diagram of maximum values of pH of wastewater of different areas

pH pH

TDS mg/L

1.3 Necessity of Laboratory Type Textile ETP:

Laboratory type effluent treatment plant is a new concept in Bangladesh. Generally ETP setup cost is high. The cost of ETP varies from Tk 1Cr to 5Cr depending upon the volume of effluent.[2] Similarly, the processing cost of wastewater in ETP varies upon the processing materials & process type. But a laboratory type ETP is easy & cheap to construct and treatment cost is also cheap. Not also the textile industries produces wastewater, but also in every university which have Textile Engineering Department & dyeing lab also produces effluents during different dyeing practical classes. After practical classes generally the effluents are discharged into the sewerage line. This effluent mixing with sewerage waste and increases the pollution rate of drain water. If we use laboratory type ETP, firstly we can treat the effluent produced from different practical classes and secondly we can easily learn how to operate ETP as like as industry. We can also learn the total treatment process of ETP that could help our future industrial job. We can collect effluents from different textile industry and treat it as like a practical class of Effluent Treatment Plant. Even now Effluent Treatment Plant is mandatory to setup of any new dyeing industry otherwise they will not get gas & electricity connection thats why it is important to know about ETP for future job life. ETP is also a part of textile undergraduate engineering syllabus. So it is important to know about ETP and in that case a laboratory type ETP can give all solution. Any research type activities related to wastewater can be easily done in laboratory. A laboratory ETP construction cost is about Taka 5,000 to 6,000 with chemical cost. Its construction process is easy and operating cost is very low as compared to industrial ETP.

2. Construction of Laboratory Type Textile ETP:

Construction of laboratory type textile ETP is an innovative work. At the beginning, most important thing is make a layout plan according to model shape & area. Then calculate the different tank areas according to its process. And after layout another important thing is purchasing of construction materials. Construction materials are purchased from three different places in Dhaka. Pumps and cork sheets are purchased from Kataban area, different plastic boxes from old Dhaka and remaining materials from Badda area. Chemicals are purchased from Hatkhola road. After collecting all raw materials, at first frame and boundary of plant was constructed according to plan layout. After that cork sheets are placed inside the wood frame and cut it according to different sizes of plastic box. Cork sheets are attached by adhesive & then the boxes are placed inside the cork sheet. Air flow pipes and bubble creators are attached by joint & adhesive respectively in different tank. At final stage a thin polyethylene sheet is attached on the cork sheet as a waterproof surface.

Figure 5. Different steps of Construction of Laboratory Type Textile ETP.

2.1 List of costs of accessories:

Table 2. List of costs of accessories* Serial
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21

Product name
Air pump Filter pump Hard board Ply Wood Board pin Cork sheet Hekso bleed Measuring tape Adhesive Anti cutter Polythin sheet Plastic box Dropper Multi plug Polyester net PVC pipe PVC Pipe joint Air flow pipe Key & joint Air bubble creator Making & other cost 1 3

Quantity

Origin
China China Bangladesh Bangladesh Bangladesh Bangladesh China China India China Bangladesh Bangladesh Bangladesh China Bangladesh Bangladesh Bangladesh China Bangladesh China

Unit price
200 400 300 15 140 110 15 25 60 35 15 5 300 5 25 5 8 5 50 -

Amount (BDT)
200 1200 300 150 15 180 110 30 25 120 35 30 280 25 300 5 50 50 40 40 250 300

1 (8 x 4) 5 100 gm 2 (4 x 8, 1) 1 (4 x 8, 3/4) 2 1 2 1 2 7 5 1 1 2 (1/2 dia) 10 5 yds 10 5 -

Total

3735

*Prices may be changed as per market value.

Table 3. List of Costs of Chemicals

Chemicals Cost/Kg (BDT)

Lime Ferrous sulfate Polyelectrolyte De colorant Hydrochloric acid

150 200 800 16 25

2.2 Plant Layout: Drawing Design

C A B D

J G K E

A B C D E F G H I J K L

Screening unit Equalizing unit Primary clarifier Oxidizing unit Decoloring unit Secondary clarifier Sludge processing unit Storage tank Outlet Input power plug Power unit Air compressor pump Water Pump Liquid flow pipe

L F H I

Overflow pipe Power cord Air flow pipe Bubble creator pipe Chemical dosing unit

2.3

Plant Layout: Image

2.4 Capacity of Different Tank:

105 cm

Name B 2.5 L A 5.0 L C 7.0 L B D C 80 cm D E E F G 0.5 L 0.5 L F G H Primary Clarifier Oxidation Tank Decoloring Unit Secondary Clarifier Discharge Sludge process unit Equalization Tank A Screening

Capacity 1.0 L 5.0 L 2.5 L 7.0 L 1.5 L 0.5 L 0.5 L 0.5 L

1.5 L

2.5 Devices Used in ETP Model: Oxygen pump:[4]

Long lasting performance Two speed control system Twin outlet Energy saving design Low noice and big output

Table 4. Specification of Oxygen Pump

Country of origin Manufacturer company Model no. Input power Output Pressure China Song Bao Electric Appliance Co. Ltd. SB-348A AC 220-240V 5W 2 x 4L/min 0.02 x 2 Mpa

Internal filter pump:

Long lasting performance Suitable for fresh & salt water Fully submersible Energy saving design Low noice and big output

Table 5. Specificaltion of Filter Pump

Country of origin Manufacturer company Model no. Input power Output flow

China Song Bao Electric Appliance Co. Ltd. WP-1200F AC 220-240V 15W 880L/Hr (max)

3. Experimental:
In laboratory, three samples were analyzed. Three samples were tested in three separate days. High pH obtained in all samples and got standard results after treatment. To avoid contamination the ETP cleaned properly before treatment of each new sample. pH, color & odor of samples were analyzed. BOD, COD, TDS, TSS etc values could not be analyzed in laboratory due to unavailability of instruments. These tests required high cost and could not manage.

Figure 6. Experiment with Laboratory type Textile ETP

3.1

ETP Flow Chart:

Influent

Screening

Equalization Tank

Primary Clarifier

Oxidation Tank

Decoloring Unit

Sludge processing unit

Secondary Clarifier

Discharge

3.2

Treatment Processes:

Total treatment process contains following steps:

3.2.1 Screening:
The raw waste is passed through a manual bar screen to remove floating suspended matters like polythene bags, rags etc. The bar screen is cleaned manually by hand. In this model collected wastewater is passed through the screening unit to the equalization tank. Mainly there are no any coarse particles used in laboratory.

Figure 7. Screening & Equalization tank

3.2.2 Equalization:
The screened waste is then collected in the equalization tank. In equalization tank the wastewater is kept 2 hours for cooling. The equalization tank is provided with air grids to keep the suspended solids in suspension and to ensure proper mixing is achieved. The air grids are provided by bubble creator connected to air blower.

3.2.3 Primary Clarifier:

The equalized effluent is then pumped into the primary clarifier for coagulation, flocculation and pH correction. The pump situated in the equalization tank & flows wastewater when switch on. In this unit liquid waste is treated with lime, ferrous sulfate or alumn and polyelectrolyte so that sludge is separated through coagulation and flocculation. Precipitated sludge is passed to sludge processing unit. pH can be controlled by adding concentrated hydrochloric acid in between coagulation and flocculation processes. The pH is kept around from 6.5 to 7.5. This tank is also provided with air grids to keep the suspended solids in suspension and to ensure proper reaction of coagulation and flocculation processes. The air grids are provided by bubble creator connected with air blowers. The total reaction time is taken about 1.5 hours to 2 hours.

Figure 8. Primary Clarifier

Table 6. Retention Time & Chemical dosing

Steps Equalization Primary clarifier Oxidation De coloring unit Secondary clarifier Retention Time 2 hours 1.5 - 2 hours 1 hour 1 hour 2 hours Chemicals Dosing Lime Ferrous sulfate Polyelectrolyte De colorant Hydrochloric acid 1 g/L 1 g/L 1 g/L 10 ml/L 20 ml/L

3.2.4 Oxidation:
The upper level liquid waste of secondary clarifier is passed to oxidation tank and precipitated sludge is then separated to sludge processing unit by pump. The biological treatment is designed on extended aeration principle. The aeration is provided with fixed type surface aerator for providing the required oxygen for the biological degradation of organic pollutant. In our experiments we could not manage bacteria & thats why oxidation process was skipped from our experiments. In this unit the liquid waste is kept about 1 hour for proper reaction of chemicals.

Figure 9. Oxidation Tank

Figure 10. Decolorant Tank

3.2.5 Decoloring unit:

After biological treatment the liquid waste is passed to the decoloring unit by pump. In this tank required amount of decoloring agent is dosed to remove the organic color of wastewater. The reaction time is about 50 to 60 minutes.

3.2.6 Secondary Clarifier:

After decoloring unit the liquid waste is passed to the secondary clarifier. In secondary clarifier the upper layer of the liquid waste remains stationary and liquid waste is passed from the lower level of the secondary clarifier to the sludge processing unit so that remaining dissolved solids are separated as sludge.

Figure 11. Secondary Clarifier

Figure 12. Sludge Thickening Unit

3.2.7 Sludge Processing Unit:

The sludge underflow from the primary and secondary clarifier is taken into sludge drying beds for dewatering. The dewatered sludge is scrapped manually and disposed off suitably.

3.2.8 Discharge:
Over flow of liquid from the secondary clarifier is stored in discharge unit. This water is then drain out to the environment.

Figure 13. Discharge Unit

3.2.9 Experiment Results: Sample 01

Table 7. Validation based on experimental results Parameters
Color pH Odor

Before treatment
Deep Blue 11.0 Odorless

After treatment
Pale Blue 7.0 Odorless

Remarks
Decolorised pH maintained as discharge limit

Figure 14.Before pH 11 & after pH 7.0

Figure 15.Before Decolorization & after Decolorization

3.2.10 Experiment Results: Sample 02

Table 8. Validation based on experimental results Parameters
Color pH Odor

Before treatment
Deep Red 10.0 Odorless

After treatment
Pale Red 7.0 Odorless

Remarks
Decolorised pH maintained as discharge limit

Figure 16.Before pH & 11 after pH 7.0

3.2.11 Experiment Results: Sample 03

Figure 17.Before Decolorization & after Decolorization

Table 9. Validation based on experimental results Parameters

Color pH Odor 9.0 Odorless 7.0 Odorless

Before treatment

After treatment

Remarks
Decolorised pH maintained as discharge limit

Figure 18.Before pH 11 & after: pH 7.0

Figure 19.Before Decolorization & after Decolorization

4. Results & Discussion:

Treatment of effluent from textile dyeing industries is required to meet the national and international effluent discharge standard. It is required to meet the national standard to abide by the rules set up by the Government and to meet the international standard to comply with the standard setup by the buyers. In Bangladesh, Department of Environment is the regulatory body to monitor and control the pollution from the industrial discharge. It has set up the industrial discharge standards for the industries.

Table 10. Inland Surface Limits for textile liquid waste according to the National Effluent Quality Standards (NEQS) guided by DoE of Bangladesh.[5]

Parameters pH BOD 5 (20 C) COD TSS TDS Oil & Grease

o

Limits 6.0-9.0 50 mg/L 200 mg/L 100 mg/L 2100 mg/L 10 mg/L

DoE has not set up any color standard for the industries. Although as a health and environmental issue color is less of a concern than many of the other parameters, it is an issue in dye house effluent because unlike other pollutants it is so visible. Reducing color is therefore important for the public perception of a factory.

Our laboratory experiments got standard limits after treatment in each sample. Laboratory treatment has given result on pH, color, temperature & odor of samples. TDS, TSS, BOD, COD was not found because of unavailability of instruments. Table 11. Lab Experiment Result Based on pH.

Sample No. Before Treatment Sample 01 Sample 02 Sample 03 11.0 10.0 9.0

pH After Treatment 7.0 7.0 7.0

Remarks Satisfactory Satisfactory Satisfactory

Table 12. Lab Experiment Result Based on color.

Sample No. Sample 01 Sample 02 Sample 03 Deep Blue Deep Red Deep Yellow

Color Before Treatment After Treatment Pale Blue Pale Red Pale Yellow

Remarks Satisfactory Satisfactory Satisfactory

High pH values were obtained in every sample before treatment in ETP model and after treatment in this model standard limits were found on each sample. It proves that the treatment process was correctly done as like factory. Now a day it is essential to know about textile wastewater management as a textile engineer. To this view point a laboratory type textile effluent treatment plant can be a good solution to know about

textile wastewater management system. By this ETP model any kinds of wastewater related treatment can be done.

Practical Classes: By this ETP model practical classes about textile wastewater management can be taken. It is helpful for a student to know easily how textile wastewater is treating. In fact now a day textile wastewater management is a part of syllabus of undergraduate student. Thats why every university which has Textile engineering department is essential to have an ETP model in their laboratory. Dyeing wastewater treatment: Wastewater from textile dyeing laboratory is directly discharged on sewerage line during practical classes. This effluent mixing with sewerage waste increases the pollution rate of drain water. But this wastewater can be stored in a drum and can treat by this ETP model in laboratory. Research on wastewater: Any research type activities related to wastewater can be easily done in laboratory by using this ETP model. Wastewater collected from different areas can be analyzed by this model.

5. Conclusion:
In the way of employment-intensive industrialization, textile industries are playing an utmost important role offering tremendous opportunities for the economy of Bangladesh. But hasty and unplanned clustered growth of industries leads to adverse environmental consequence in an alarming way. Large quantity of water associated with the production of a number of dyeing and textile industries releases toxic wastewater rich in dye and chemicals to the environment that result in sever water body pollution. For undergraduate studies in Textile Engineering there are several Universities in public and private sectors launched B.Sc in Textile Engineering program. At the department of Textile Engineering dyeing laboratory is essential for practical classes in wet processing technology. Effluent is generated after dyeing lab classes in Universities. It is also essential to treat this effluent. So laboratory type ETP is mandatory in these universities to treat wastewater generated after practical classes. This type of ETP designing, construction and validation methods reported in this assignment. So it would be nice if this type of innovative laboratory type ETP is constructed and used for lab wastewater treatment.

6. Acknowledgements:
By the name of Allah at first I would like to thank Bangladesh Textile Today for arranging such a challenging competition. It is a great opportunity for me to participate in this competition. In this second step of Textile Talent Hunt, my paper design subject is Designing, Construction and Validation of Laboratory Type Textile Effluent Treatment Plant. It is a good subject and awareness for people who are thinking about the textile wastewater management system. I would like to give thank my Supervisor Dr. Arun Kanti Guha for his support to make this paper successful. Without his support it will more difficult to make this paper successful. I am also grateful to Prof. Fakhrul Hasan Murad, Chairman, Department of Textile Engineering for financial and moral support to complete this work. After him I would like to give thank our laboratory teacher Mr. Yeamin Sarker. He helped me a lot to collect wastewater. In this paper I have tried to give my best performance to make this paper successful. Again thank to Bangladesh Textile Today for arranging Textile Talent Hunt -2010. I think in future they will organize more programs which will help us in our future life.

7. References:
1. Arun Kanti Guha, Md. Shariful Islam, Environmental Management in Textile, Bangladesh Textile Today, 2(1), 43-48 2. A.S.M. Tareq Amin, Md. Ershad Khan, Surface Water Pollution: Contribution of Textile Sector and Way Out, Bangladesh Textile Today, 2(3), 16-20. 3. Md. Imdadul Haque, Arun Kanti Guha, Characterization of Textile Wastewater of Different Areas of Bangladesh, Bangladesh Textile Today, 3(1), 28-31. 4. http://www.newsobo.com 5. http://www.doe-bd.com