BKC3683 WASTEWATER TREATMENT

MINI PROJECT

WASTEWATER TREATMENT PLANT FOR TEXTILE WASTEWATER

GROUP 4:
NUR ATIQAHFARANI BINTI MOHAMED AZAMAN KA17269
NUR ADILA AIDA BINTI SALAHUTHEEN KA17264
EMILIA NURDIANA BINTI AZIDEE KA17268
FATIN NUR LIYANA BINTI MOHD ZAMRI KA17254
SITI NUR ATASHA BINTI MOHAMAD KA17247

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A.INTRODUCTION AND LITERATURE REVIEW

In textile manufacturing, there are 4 stages involved, which are yarn formation, fabric formation,
wet processing and fabrication (Madhav et al., 2018). Yarn formation and fabric formation are considered
as dry process and it is applied at the starting of the production and no water is used to run this process.
Dry process includes texturizing, warping, spinning, slashing and knitting. After dry process is done, then
it proceeds to wet process. The pollutants released in wet processing are detrimental to the environment,
and wet processing consists of few other processes. The processes included under wet processing are
sizing, de-sizing, sourcing, bleaching, mercerising, dyeing, printing and finishing techique (Liu et al.,
2010) and each process discharges different types pollutants. For example, during dyeing process, it
releases metals, salts surfactants, colour in alkaline conditions (Holkar et al., 2016).

The textile industry wastewater is heavily loaded with residual dyes, surfactants and sometimes
metals. The function of surfactants in textile industry is they are used as antistatic, untangling and
softening agent. This industry consumed considerably high amount of processed water. It also produces
large amount of highly polluted discharge water, thus it is considered as harmful to the environment
(Tufekci et al,2007). Moreover, the wastewater may contaminate the nearby soil, sediment and surface
water other than its unpleasant appearances and toxicity (Yaseen & Scholz,2019). The textile wastewater
effluents are high in colour, pH, oil and grease, suspended solids (Pala & Tokat, 2002), chemical oxygen
demand (COD), biochemical oxygen demand (BOD) (Yaseen & Scholz,2016), metals (Sharma et al.,
2007), temperature (Dos Santos et al., 2007) and salts. It is also classified as low biodegradability
wastewater (Alinsafi et al., 2005).

B.SYNTHESIS ROUTE AND OBJECTIVES

BI. Problem statement

Textile industry is one of the largest water-consuming industries in the world, and its wastewater contains
many pollutants such as dyes, degradable organics, detergents, stabilizing agents, desizers, inorganic salts,
and heavy metals. There are many sulphide compounds used in textile industry that are environmental
concerns because of their hazardous nature. Chemical additives in textile effluent contain a high
concentration of organic and inorganic compounds. Due to concerns about environmental pollution, the
textile industry must establish on-site or on-site treatment plants to treat effluents prior to their discharge
into water. Standards for effluent from the textile industry are listed in Table 1.

Table 1: Table of Effluent from Production Line and Discharge Standard

Parameter Effluent from Production Discharge Standards
Line Range To Achieve
pH 7.5-14 5-9
Total Suspended Solids (mg/L) 2540-3930 40
Biochemical Oxygen Demand (mg/L) 80-340 30
Chemical Oxygen Demand (mg/L) 240-1180 50
Total residual Chlorine (mg/L) 90-190 1
Oil & Grease (mg/L) 14-22 5
Total Dissolved Solid (mg/L) 2300-3555 10

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 BII. Synthesis route

In general, the production of textile fibre products involves many stages of mechanical processing, such as
spinning, weaving, yarn preparation, knitting and garment production. These processes are isolated from
wet treatment processes used in textile manufacturing such as pre-treatment (de-sizing, scouring,
bleaching and mercerizing), dyeing, printing and finishing. Various treatment methods have been used to
treat textile wastewater such as adsorption, ion exchange, membrane filtration [reverse osmosis (RO),
ultrafiltration (UF) and nanofiltration (NF)], ozonation, evaporation (multiple-effect evaporation,
mechanical vapor compression and direct contact evaporation) electrochemical oxidation, flocculation,
phytoremediation, photochemical and crystallization.

Table 2: Table of Synthesis Route

Treatment Methods ROUTE 1 ROUTE 2 ROUTE 3

Physical method Sand Filter Membrane Ion exchange
Biological method Aerobic process Anaerobic process Anaerobic process
Chemical method Coagulation& Fenton oxidation Ozonation
Flocculation
Removal Yield High Removal Moderate Removal Moderate Removal
Efficiencies Efficiencies Efficiencies
Detention Time Short Longer Longer
Advantages • Dewatering • Metal dye • Selective removal
characteristics selective of metal ion
• Lower operating • Small space • lower number of
cost requirements metal ions
• Low production of removed
sludge
Disadvantages • Disposal problems • Concentrated and • Expensive
• High cost of high sludge (synthetic resins)
chemicals reagent production • large-scale
• Sensitivity to toxic • High capital cost application
organic dye • Incapable of • lower number of
treating large metal ions
volumes removed
• Membrane fouling • high maintenance
and operational
costs
• High production of
sludge

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 Table 3: Table of Site Selection

Site Selection Pulau Pinang Johor Selangor

Regulations & Policy Stable Stable Stable
Waste & Disposal Better Good Good
policy
Strategic location Available clinic, Available clinic, Available clinic,
school facilities school facilities school facilities
Labour supply High High High
Rating The Best Good Good

Since Route 1 has the best rating compared to the others, hence we decided to choose Route 1 to be
applied in our waste water system. Since, Pulau Pinang has the highest rating compared to the others two
sites. Thus, it is decided to choose Pulau Pinang, Malaysia as the manufacturing site. Social facilities in
some areas could sustain social cohesion and the well-being of the population. Pulau Pinang is facilitated
by hospitals, primary schools, high schools and banks.

BIII. Selection of the technology

Cotton-textile manufacturers have used a variety of adaptations of wastewater treatment systems.

Activated-sludge techniques are among the most widely used; the moderate or even high biodegradable
organic content of wastewater makes the above techniques cost-effective. Aerobic bioprocesses are
broadly acknowledged in tropical countries for economic reasons, and full-scale systems have been
successfully introduced in countries facing serious problems in the treatment of textile wastewater.
Chemical coagulation/flocculation accompanied by precipitation has been commonly used for its
efficiency and simplicity. Several textile manufacturers use this process, in particular in combination with
chemical oxidation, activated sludge treatment and other methods.

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 Raw textile waste water

Equalization tank

Coagulation & Flocculation

Clarifier

Buffer

Aeration 1

Aeration 2

Clarifier

Final Discharge Sludge holding tank

Filter Press

Disposal

Figure 1: Flowchart of selected system

BIV. Objectives

1. To study the scenario on water pollution caused by the textile finishing industry in Malaysia,
the characteristics of textile effluents and the environmental impacts contributed by the
industry.
2. To design a wastewater treatment systems that can be labelled cost-effective and to introduce
chemicals that are less toxic or can be easily handled.
3. The select the best plant location.

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C. PFD

Figure2: Figure of Process Flow Diagram of Textile Wastewater Treatment Plant

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D. 3D SCHEMATIC DIAGRAM

Figure 3: Figure of 3D Schematic Diagram of Textile Wastewater Treatment Plant

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E. MECHANISM AND OPERATION PARAMETER

Table 4: Table of Mechanism and Operation Parameter for each Unit

No Unit Mechanism Operation
Parameter
1.
Collection Tank is the tank at where wastewater Pressure : 1 atm
(WWT) from production stream is discharged. Temperature: 25°C
This tank works by storing wastewater before pH : WWT pH
proceeds for treatment. (7.5-9.5)
2.
Grit chamber slows down the WWT flow so that Pressure : 1 atm
solids will settle out of the water. Grit chamber Temperature : 25°C
consists of a cylindrical tank in which the flow pH : WWT pH
enters tangentially, creating a vortex flow (7.5-9.5)
pattern. Grit settles by gravity into the bottom of
the tank called a grit hopper while effluent exits
at the top of the tank.
3.
Effluent from the collection tank comes to the Pressure : 1 atm
equalization tank. This tank act as buffer. This Temperature : 25°C
tank collects the effluent that comes at widely pH : WWT pH
fluctuating rates and position to the rest of the (7.5-9.5)
ETP at steady flow rate. During the peak hours
ETP comes at high flow rate. The equalization
tank stores this effluent and let it out during the
non-peak time when there is no or little
incoming effluent.
4.
Coagulant Tank stores coagulation reagent. This Pressure : 1 atm
tank supply coagulant reagent based on the Temperature : 25°C
volume of influent into the Flash Mixing Tank.
5.
Flocculant Tank stores flocculation reagent. This Pressure : 1 atm
tank supply flocculant reagent based on the Temperature : 25°C
volume of influent into the Flash Mixing Tank.
6.
Flash mixing will evenly distribute coagulating Pressure : 1 atm
and flocculating reagents in water, allowing Temperature : 25°C
coagulant and flocculant to form. When th pH: 7.5
reagent mix equally with WWT, the positive Agitator Speed :
charge of the coagulant neutralizes the negative Moderate
load of dissolved and suspended particles in the
water. As this reaction occurs, the particles bind Coagulant Dosage:
together, coagulate and flocculate. Under the 1g/L CaO,
optimum conditions, the turbidity and chemical 1g/L MgCl2.7H2O,
oxygen demand (COD) removal efficiencies
were 96.4% and 83.5%. Total dissolved solids Flocculant Dosage:

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 (TDS), heavy metal and colour from effluent of 250mg/L Al2(SO4)3
the industry also remove.
7.
Primary clarifier slows down the water and Pressure : 1 atm
removes the solids that settle on the bottom with Temperature : 25°C
a rotating sludge raking system. It also removes Detention Time :2 hrs
solids that float to the surface of the tank with its
rotating rake skimming system.
.
8. This tank realise a consistent volume and a
consistent quality. Buffer Tank implementation Pressure : 1 atm
allows further purification processes to run as Temperature : 25°C
effectively as possible. The buffer can be in-line
or off-line. In-line buffering involves the entire
quantity of wastewater flowing through the
buffer tank.
9.
Aeration provides oxygen to bacteria for treating Pressure : 1 atm
and stabilizing the wastewater. Oxygen is needed Temperature : 35°C
by the bacteria to allow biodegradation to occur. pH: 7.5
The supplied oxygen is utilised by bacteria to Time: 6 hours
break down the organic matter containing carbon
to form carbon dioxide and water. Here, organic
matter removed.
10.
Secondary clarifier slows down the water and Pressure : 1 atm
removes the solids that settle on the bottom with Temperature : 25°C
a rotating sludge raking system. It also removes Detention Time :2 hrs
solids that float to the surface of the tank with its
rotating rake skimming system.
11.
This tank to adjust pH of WWT from 7.5 to 6 by Pressure : 1 atm
adding hydrochloric acid. When an acid and a Temperature : 25°C
base react, it releases equal quantities of H+ ions pH: 6
and OH- ions, neutralization results. H+ ions and
OH- ions combine and neutralize each other.
12.

In pressure sand filter influent flows downwards Pressure : 1.36atm

through the filter bed and as the suspended Temperature : 25°C
matter at which been treated by addition of a
coagulant like alum is retained on the sand
surface and between the sand grains
immediately below the surface. There is a steady
rise in the loss of head as the filtration process
continues and the flow reduces once the pressure
drop across the filter is excessive.

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13. Ozonation is for further treatment. Ozone has
good disinfection effectiveness against bacteria Pressure : 0.92atm
and viruses compared to chlorination. The Temperature : 25°C
influent pass through a venturi throat which
creates a vacuum and pulls the ozone gas into the
water or the air is then bubbled up through the
water being treated. The oxidizing properties of
ozone reduce the concentration of iron,
manganese, sulfur and reduce or eliminate taste
and odor problems. Ozone oxides the iron,
manganese, and sulfur in the water to form
insoluble metal oxides or elemental sulfur.
These insoluble particles are then removed by
post-filtration. Ozone eliminates a wide variety
of inorganic, organic and microbiological
problems and taste and odor problems.
14.
Sludge Holding Tank holds sludge and blend for Pressure : 1 atm
the thickened waste activated sludge, primary Temperature : 25°C
sludge, imported sludge, and scum before further
processing.
15. A filter comprises a set of vertical, juxtaposed
recessed plates, presses against each other by Pressure : 20 atm
hydraulic jacks at one end of the set. The Temperature : 25°C
pressure applied to the joint face of each filtering
plate must withstand the chamber internal
pressure developed by the sludge pumping
system. This vertical plate layout forms
watertight filtration chambers allowing easy
mechanisation for the discharge of cakes.
16. Sludge Disposal Tank stores sludge while Pressure : 1 atm
waiting for scheduled solid waste disposal. Temperature : 25°C

F. CONCLUSION
In the nutshell, the scenario and the characteristics of wastewater from textile industry is studied.
The effective and low cost wastewater treatment system is studied and designed. Penang is selected as the
location of the plant as Penang gives easy access for the plant. The best route is chose based on the
comparison made and advantages consideration. After study, the grit chamber is decided to be used for
pre-treatment. Grit chamber slows down the WWT flow so that solids will settle out of the water. Then,
treatment is proceeding to chemical treatment using coagulation and flocculation tank. The turbidity and
chemical oxygen demand (COD) removal efficiencies were 96.4% and 83.5%. Total dissolved solids
(TDS), heavy metal and colour from effluent of the industry also remove. Next, treatment is proceed by to
biological treatment which decides to use aeration tank and aerobic. Bacteria in the aeration tank breaks
down the organic matter. After that, pressure sand filter is decided for physical treatment remove
suspended matter. Then, ozonation process is chose for further treatment as the ozone has good
disinfection effectiveness against bacteria and viruses compared to chlorination. Lastly, sludge is going to
be handled by filter press to get the sludge cake and send to the sludge disposal tank.

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REFERENCES
Tüfekci, N., Sivri, N., & Toroz, İ. (2007). Pollutants of textile industry wastewater and assessment of its
discharge limits by water quality standards. Turkish Journal of Fisheries and Aquatic Sciences, 7(2), 97-
103.
Pala, A., & Tokat, E. (2002). Color removal from cotton textile industry wastewater in an activated sludge
system with various additives. Water research, 36(11), 2920-2925.
Yaseen, D. A., & Scholz, M. (2019). Textile dye wastewater characteristics and constituents of synthetic
effluents: a critical review. International journal of environmental science and technology, 16(2), 1193-
1226.
Yaseen, D. A., & Scholz, M. (2016). Shallow pond systems planted with Lemna minor treating azo
dyes. Ecological engineering, 94, 295-305.
Sharma, K. P., Sharma, S., Sharma, S., Singh, P. K., Kumar, S., Grover, R., & Sharma, P. K. (2007). A
comparative study on characterization of textile wastewaters (untreated and treated) toxicity by chemical
and biological tests. Chemosphere, 69(1), 48-54.
Dos Santos, A. B., Cervantes, F. J., & van Lier, J. B. (2007). Review paper on current technologies for
decolourisation of textile wastewaters: perspectives for anaerobic biotechnology. Bioresource
technology, 98(12), 2369-2385.
Alinsafi, A., Khemis, M., Pons, M. N., Leclerc, J. P., Yaacoubi, A., Benhammou, A., & Nejmeddine, A.
(2005). Electro-coagulation of reactive textile dyes and textile wastewater. Chemical engineering and
processing: Process intensification, 44(4), 461-470.
Liu, R. R., Tian, Q., Yang, B., & Chen, J. H. (2010). Hybrid anaerobic baffled reactor for treatment of
desizing wastewater. International Journal of Environmental Science & Technology, 7(1), 111-118.
Holkar, C. R., Jadhav, A. J., Pinjari, D. V., Mahamuni, N. M., & Pandit, A. B. (2016). A critical review
on textile wastewater treatments: possible approaches. Journal of environmental management, 182, 351-
366.
Madhav, S., Ahamad, A., Singh, P., & Mishra, P. K. (2018). A review of textile industry: Wet processing,
environmental impacts, and effluent treatment methods. Environmental Quality Management, 27(3), 31-
41.

Pang, Y. L., & Abdullah, A. Z. (2013). Current status of textile industry wastewater management and
research progress in Malaysia: a review. Clean–Soil, Air, Water, 41(8), 751-764.

Kaur, P., Kushwaha, J. P., & Sangal, V. K. (2018). Transformation products and degradation pathway of
textile industry wastewater pollutants in Electro-Fenton process. Chemosphere, 207, 690-698.

Sahinkaya, E., Yurtsever, A., & Çınar, Ö. (2017). Treatment of textile industry wastewater using dynamic
membrane bioreactor: Impact of intermittent aeration on process performance. Separation and Purification
Technology, 174, 445-454.

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Patel, H., & Vashi, R. T. (2015). Characterization and treatment of textile wastewater. Elsevier.

Sarayu, K., & Sandhya, S. (2012). Current technologies for biological treatment of textile wastewater–a
review. Applied biochemistry and biotechnology, 167(3), 645-661.

Pattnaik, P., Dangayach, G. S., & Bhardwaj, A. K. (2018). A review on the sustainability of textile
industries wastewater with and without treatment methodologies. Reviews on environmental health,
33(2), 163-203.

A.R. Rakmi, Characterisation and prospects for biological treatment of textile finishing wastewater, in
Waste Management in Malaysia: Current Status and Prospects for Bioremediation (Eds.:B. G. Yeoh, K.
S. Chee, S. M. Phang, Z. Isa, A. Idris, M. Mohamed), Ministry of Science, Technology and Environment,
Kuala Lumpur, Malaysia 1993, pp. 99–108.

F. Beduk, M. E. Aydin, S. Ozcan, Degradation of Malathion and Parathion by Ozonation, Photolytic

Ozonation, and Heterogeneous Catalytic Ozonation Processes, Clean – Soil Air Water 2012, 40 (2), 179–
187.

A. Baban, A. Yediler, D. Lienert, N. Kemerdere, A. Kettrup,Ozonation of High Strength Segregated

Effluents from a Woollen Textile Dyeing and Finishing Plant, Dyes Pigm. 2003,58 (2), 93–98.

V. Preethi, K. S. Parama Kalyani, K. Iyappan, C. Srinivasakannan, N. Balasubramaniam, N. Vedaraman,

Ozonation of Tannery Effluent for Removal of COD and Color, J. Hazard. Mater. 2009, 166 (1), 150–
154.

Babu, R.B., Parande, A.K., Raghu, S., Kumar, P.T., 2007. Textile technology-cotton textile processing:
waste generation and effluent treatment. J. Cotton Sci. 11, 141–153.

O’Neill, C.; Hawkes, F. R.; Hawkes, D. L.; Esteves, S.; Wilcox, S. J. (2000) Anaerobic/Aerobic
Biotreatment of Simulated Textile Effluent Containing Varied Ratios of Starch and Azo Dye. Water Res.,
34(8), 2355–2361.

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 BKC3683 WASTEWATER TREATMENT
REPORT AND VIDEO PRESENTATION

GROUP NAME : GROUP 4

GROUP MEMBERS NAME

S1 NUR ADILA AIDA BINTI SALAHUTHEEN
KA17264

S2 EMILIA NURDIANA BINTI AZIDEE

KA17268

S3 SITI NUR ATASHA BINTI MOHAMAD

KA17247

S4 NUR ATIQAHFARANI BINTI MOHAMED AZAMAN

KA17269

S5 FATIN NUR LIYANA BINTI MOHD ZAMRI

KA17254

Report (70%)

Unacceptable Acceptable Good Very Good Score

(0) (1) (3) (5)
Introduction and Very little Has the following item; Has the following item; Has the following item; X2
Literature review information or • Project Background • Project Background • Project Background
information is (Industry/company & (Industry/company & (Industry/company &
incorrect. Process description) Process description) Process description)
• Wastewater background • Wastewater background • Wastewater background
• Wastewater • Wastewater characteristic • Wastewater
characteristic characteristic
But
But Points badly organized; Report is made interesting
Unclear problem report is difficult to and easy to understand
statement and objective understand
Synthesis route Very little Has the following item; Has the following item; Has the following item; X3
and objective information or • Problem statement • Problem statement • Problem statement
information is • Synthesis route • Synthesis route • Synthesis route
incorrect.
• Selection of the • Selection of the • Selection of the
technology technology technology
• Objective (include plant • Objective (include plant • Objective (include plant
location) location) location)

But But But

unclear screening process Points badly organized; Report is made interesting
report is difficult to and easy to understand
understand

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 PFD and schematic Very little Has the following item; Has the following item; Has the following item; X3
diagram information or • Process diagram • Process diagram • Process diagram
information is • Schematic diagram • Schematic diagram • Schematic diagram
incorrect.

But But But

• Unclear process • Points badly organized;
technology
Report is made interesting
(3D or animate) and easy to
understand
Mechanism and Very little Has the following item; Has the following item; Has the following item; X3
operation parameter information or • Mechanism • Mechanism • Mechanism
information is • Operation parameter • Operation parameter • Operation parameter
incorrect.
But But But
• Unclear process • Points badly organized; Report is made interesting and
technology easy to understand
Conclusion Conclusion not Has conclusion that related to Has conclusion that related to Conclusion related to X1
related to objective objective objective with explanation objective. Main ideas are
summarized complete with
limitation.
References & citation Citing unrelated At least 5 articles cited and its At least 10 articles cited and its 20 or more articles cited and X2
articles. Useful useful content digested and useful content digested and its useful content (all article)
content digested included in the report. included in the report. digested and included in the
and included in the report.
report.
No comment on Less comment on other Able to comment and refer to
other article references other references.
Presentation (30%)

Unacceptable Acceptable Good Very Good

(0) (1) (3) (5)
Content Very little Acceptable Content. Good content. Consists all Very Good content. X1
information or important items and Consists all important
information is explanation item and explanation
incorrect.
Video style and Video style and Less fluent on the material of Some mumbling but The video is creative, clear X4
language language are not presentation. audible most of the time, and good quality of
proficiency clear presentation. S1

S2

S3
Timeliness and Poorly prepared Poorly prepared slides, & Acceptable font size good Font size large enough for X1
presentation slides, small font small font; good contrast. contrast. entire classroom good
slides & poor contrast. Over 5 minutes longer than Over 4 minutes longer than contrast. Over 3 minutes
Over 6 minutes allocated time. allocated time. longer than allocated time.
longer than
allocated time.
TOTAL /100

Comments:

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