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13th Asia Pacific Roundtable On Sustainable Consumption & Production (APRSCP)
SCP as a strategy for national energy,
water and food security
TOPIC 3 : Cleaner Production & Cost Reduction in Waste Management
By Lim Swee Choon Envilab Sdn Bhd
Cleaner Production & Cost Reduction In Waste Management
• High Strength Industrial Waste
• Treatment of High Strength Industrial Waste
• Vacuum Evaporation Technology
• Cleaner Production with Vacuum Evaporator
• Cost reduction in waste management
• Summary
Content :
•Air Pollution
•Water Pollution
•Environmental Pollution
All Industries Are Polluting !!!
How to make it sustainable ?
•End Of Pipe process
•No proper waste management system
• Increase Energy Consumption
• Increase Material Consumption
•Reduce Environmental Quality
•Tendency of illegal damping/discharge
Current Situation
Getting worst due to high demand
Definition :
• Organic (COD) > 10,000 mg/l
• Heavy Metals > 10,000 mg/l
• Oil & Grease > 10,000 mg/l
• Suspended Solids > 20,000 mg/l
High Strength Industrial Waste
Most challenging in Treatment of Industrial Waste to your business
Example :
• Ink Waste
• Photographic Developer
• Machine Waste Coolant
• Concentrated waste Chemicals
• Factory reject/expired products
• Reject from RO
• Electroplating bath
• Detergent/Cleaning bath (surface degreasing)
High Strength Industrial Waste
• Dispose at original volume & concentration
• High disposal cost (large volume)
• Convert small problems into somebody big problems
• NO treatment hassle
• Zero Capital cost
High Strength Industrial Waste
Treatment Option A Direct Disposal to Waste
Management Centre.
• Chemical & Biological treatment
• Complicated process
• Performance affected by strength of waste
• High chemicals cost
• High sludge disposal cost
• Difficult to achieve effluent discharge compliance
• Large foot print
High Strength Industrial Waste
Treatment Option B Conventional Processes
• Volume reduction
• Low disposal cost (low volume)
• Reuse of water or concentrate
• Simple process (physical)
• Performance regardless of waste strength
• Low foot print (compact system)
• High Capital cost
High Strength Industrial Waste
Treatment Option C Vacuum Evaporation
The Technology of Vacuum Evaporator
•Principle of boiling in a vacuum condition
•Less energy is needed (150 – 180 watt/liter)
•Evaporation at 35 – 45 °C
•Heat Pump (refrigerant compressor)
Process Description
Air Conditioner System
Vacuum Evaporator - Process Flow
Multi Effect - Process Flow
3° STAGE 1° STAGE 2° STAGE
ARIA
COOLING TOWER
HOT
WATER
V-NT Series
• Vertical vacuum evaporator
• Concentrates up to 20 times
• Fully automatic
• Heat pump technology
• Refrigeration cycle with
ecological refrigerant gas
• Use of special stainless steel
alloys for aggressive effluents
Vacuum Evaporator - Concentrator
Production Capacity
100 – 25,000 litres/day
ME Series
• 2 or 3 vertical vacuum
evaporators in series
• Concentrates up to 20 times
• Fully automatic
• Use of special stainless steel
alloys for aggressive effluents
• Treatment of larger volumes of
effluent
Production Capacity
10,000 – 50,000 litres/day
Vacuum Evaporator - Concentrator
ME Series
• Possible to use any alternative
energy source: (hot water,
steam, oil and by-products)
• Energy saving : energy only
needed to feed 1st evaporator,
• Use of cooling system to
condense steam produced by
last evaporator
Production Capacity
10,000 – 45,000 litres/day
ME Vacuum Evaporator
ES Series
• Horizontal vacuum evaporator
• Concentrates to dry mud/crystals
• Fully automatic with manual discharge
• Heat pump technology
• Refrigeration cycle with ecological
refrigerant gas
• Use of special stainless steel alloys for
aggressive effluents
Production Capacity
100 – 1,000 litres/day
Vacuum Evaporator - Dryer
Vacuum Evaporator - Dryer Model
Treatment Of Organics Waste
Treatment Of In-Organics Waste
Typical Process Reuse/Post
Treatment or Discharge Distillate Vacuum
Concentrator (1500 – 50,000 l/day)
High Strength Wastewater
Vacuum Dryer (250 – 1000 l/day)
Sludge/Cake (Disposal)
Concentrate (Reuse/disposal)
C&G Vacuum Evaporator
• Custom designed to meet specific requirements.
• Fully automatic working cycle.
• Extremely compact construction.
• Can operate using electric energy or heat source.
• Low energy consumption (yield 150 -180 W/l)
• No fumes or smell – enclosed system
• 24 hour performance.
• Simplicity and ease of operation and maintenance.
• Galvanic industries
• Foundries: die-casting, wire-drawing
• De-greasing washes with alkaline and detergents
• Graphic arts –developer waste
• Food industry
• Pharmaceutical
• Chemical (organics waste)
• Radioactive wastewater
• Paints waste
Main Areas of Application
All type of high strength industrial waste
•Business points
•Cost Benefits
•Environmental
•Resource Recovery ???
Incentives to use new technologies
Application of
Vacuum Evaporator in Cleaner Production
Objectives :
•To create a close-loop in the Nickel line.
•To install a process of “zero” discharge of nickel into the environment.
•To install a process to recover the precious raw materials and water
Ref: Vitri Electro-Metalurgica, Spain
Recovery of Chromium or Nickel
Recovery system and “0” discharge of nickel
Nickel bath
Rinsing Tanks
Chemical treatment
Discharge
Old Process Raw material
Rinsing water
Sludge
Nickel bath
Rinsing Tanks
Vacuum Evaporator
New Process Raw material
Distillate
Concentrate
Raw materials Old Process New Process
Nickel chloride 12.1 kg/year 1.6 kg/year
Nickel sulphate 7.02 kg/year 480 kg/year
Boric acid 3.9 kg/year 220 kg/year
Nickel anodes 10.88 kg/year 6.4 kg/year
Sludge from treatment plant 40.68 mt/year 12.64 mt/year
Cost of Raw Material 236.6 Thousand €/year 95.90 Thousand €/year
Treatment cost of wastewater 13.6 Thousand €/year 6.3 Thousand €/year
Total cost 250.2 Thousand €/year 102.2 Thousand €/year
Total Saving 148.0 Thousand €/year (12.3k/month)
Capital Investment 132.2 Thousand €
Investment return 11 months
Application of
Vacuum Evaporator Treatment of Coolants Waste
Cycle of Used Coolant without Vacuum Evaporator
Vacuum Evaporator – Coolant Waste
Investment Return
ROI ≈ 14 month
Vacuum evaporator
V-NT 3500
Concentration factor 10
Capacity of evaporator
(water treated Litres/hour
146.44
Cost of electric energy
(€/kWh)
0.078
Energy used for each litre
of distillate produced
(kW/l)
0.15
Cost of disposal of
concentrate (€/l)
0.146
Cost of disposal of
wasteweater as such
without the use of an
evaporator (€/l)
0.073
INITIAL INVESTIMENT (€) 92,000
0
10000
20000
30000
40000
50000
60000
70000
80000
90000
100000
110000
120000
130000
140000
150000
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
MONTHS
EURO
Disposal of untreated wastewater
Using C&G Evaporator
Application of
Vacuum Evaporator in Treatment of Paints Waste
Application of Vacuum Evaporator (Paints Waste Treatment)
ROI - Paint Waste Treatment Description Running Cost / month RM
Consumable
Electricity
Antifoam/Carbon
Spare parts cost
(average)
201.6 kWh @ RM 0.355/kWh @ 30 days
About 5kg/100 kg (monthly)
Level sensor, Pump Seal
2,147.00
1125.00
350.00
Scheduled
Waste
Concentrate from
Vacuum Evaporator
Waste is concentrate at around 10
times,
@ 1,680 L/month
Disposal Cost @ RM 2.00 / L
3,360.00
Total operation cost per month 6,982.00
Disposal cost for 14,400 L/month @ RM 2.00 / L (Without Evaporator) 28,800.00
Total saving per month 21,818.00
Investment cost 300,000.00
ROI 14 months
Paint Waste Treatment Plant
Application of
Vacuum Evaporator in Treatment of Organics Waste
Organics Waste Treatment
Production Plant Up-Set
Production Plant Normal
ROI - Organics Waste Treatment Description Running Cost / month RM
Consumable
Electricity
Antifoam/NaOH
Spare parts cost
(and other cost)
1269.6kWh/day @ RM 0.38/kWh @ 30
days
About 10kg/2000kg monthly
Level sensor, Pump Seal, Gasket,
operator
14,473.00
6,250.00
7,500.00
Scheduled
Waste
Concentrate from
Vacuum Evaporator
Waste is concentrate at least 8x times,
@ 18,750L/month
Disposal Cost @ RM 1.00 / Liter
18,750.00
Total operation cost per month 46,973.00
Disposal cost for 150,000L/month @ RM 1.00/Liter (without evaporator) 150,000.00
Total saving per month 103,027.00
Investment cost 950,000.00
ROI 9 months
In Summary
Vacuum Evaporation Technology
Reduce Waste Disposal cost/Environment Impact
Recycle of water or salt from wastewater (3R)
Achieving Cleaner Production & Reduce Pollution
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