zaid alanber_finalproject
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Final Project Report
Project Title
(in arabic and english)
SOLVENT ROCOVERY AND WASTEWATER TREATMENTSTUDY IN KILANI PAINT MANUFACTURING INDUSTRY
ParticipantName
(in arabic and english)
Zaid Ahmed Al-Anber
Company Name(in arabic and english)
Kilani Paints Industrial Commercial est.
Sponsor
Dec. 1 2009
Faculty
For
Factory
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Table of Contents
SUMMARY (in Arabic and English). .1
1.0 Section 1.....................................................................................................3
INTRODUCTION
2.0 Section 2 .....................................................................................................8
PROBLEM STATEMENT AND OBJECTIVES
3.0 Section 3 11
POLLUTION PREVENTION POTENTIAL
4.0 Section 4........................................................................ ..13
DESCRIPTION OF THE PROCESSES OF WASHED SOLVENT
5.0 Section 5....................................................................................................23
DESCRIPTION OF THE PROCESSES OF WASTWATER
6.0 Section 6....................................................................................................30
ECONOMIC EVALUATION
7.0 Section 7....................................................................................................33
CONCLUSION
8.0 Section 8....................................................................................................34
SUSTAINABILITY STUDY FOR SOLVENT RECOVERY
9.0 Section 9....................................................................................................37APPENDICES
Appendices 1: Physical properties of solvents
Appendices 2: AttachmentsA. Approvals and Acceptance letter of the project output
B. Poster < in the FFF format>
C. Faculty and Factory surveysD. Approval of the 20% payment
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KILANIS PRODUCTS
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SUMMARY
At the beginning of the study, I was concentrated on crucial problem which
is the recovering and reusing of solvent (such as Toluene) in the Kilani
factory. But during my visiting to the Kilani Factory, I found another
problem which is the wastewater. Therefore, I included the treatment of
paint industrial wastewater in this study as well.
Actually the solvents and paint wastewater were discarded into the public
sewerage network. These cause environmental and economic problems.Therefore, reducing and recovering the quantity of solvents waste and
treatment of paint wastewater are beneficial for the owner of the plant as
well as for the environment.
Our objectives were handled these problems by minimizing and recovering
the solvents wastes and treatment of paint wastewater.
The purpose of the solvent recovery process is to separate the solvent
from paints and impurities to produce a solvent can be reused for the
original application and different purposes in Kilani factory. Our process was
involved a physical treatment which is sedimentation followed by
distillation of solvent.
Based on our experimental results the installation of a distillation unit can provide at least
90% solvent recovery from waste of solvent. We can an approximate, save of $20,000 per
year.
The purpose of paint wastewater treatment is to separate the water from paints and impurities
to produce water can be reused in different industrial purposes in Kilani factory. Our process
was only involved a physical treatments which are sedimentation and then coagulation
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process. About 85% of water was recovered by coagulation process. We can an approximate,
save of $4000 per year.
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.
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. 90. %
$ 20000 .
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85$ %4000
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SECTION 1
INTRODUCTION
COMPANY BACKGROUND
Kilani paints Company is owned by official Jordanian organizations. It is located in
Mafraq with 45000 m2 land. 200 employees in over 10 locations around in the Middle East
are joining the Kilani Paints. The production of paints began effectively in 1974 in Jordan.
The Kilani vision is to operate successfully in all the Middle East markets through:
Customers are our partners of success.
Change is an opportunity.
Continuous improving of our employees, knowledge and processing capabilities.
Competence through innovative products and operational excellence.
Finally commitment to sustainable development.
Kilani History as follow:
1974 paint Co. establish to distribute paints in Jordan.
1978 contribution in a local paints factory
1980 established a distribution in Irbid.
1984 established a distribution in Zarka.
1994 kilani paint lunched powder coating to be the first powder coating plant in
Jordan and the third in the Middle East, under the license of Croda Paints England.
1996 Kilani Paints launched auto and industrial paints.
1997 established in Palestine
1998 established in Sudan.
2002 kilani paint opened a regional office in Iraq.
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2006 Kilani paints opened a showroom in Zarka, Irbid and Amman to launch the
special effects paints
In general, Kilani paints produce the following:
Water based paints
Decorative paints
Oil based paints
Insulation and production paints
Auto paints
Synthetic paints
Auxiliary paints
Powder coating paint
Nitrocellulose paints
Special effect powder.
Champion Glue, white spirit, Adhesive, Sperto, and others
KILANIS PAINT PROCESS
Paints are manufactured in batch blending tanks according to specific recipes. The Paint
Factory Production facility inKilanican be separated into two distinct areas:
Water Based
Solvent Based such as Toluene, Xylene, Methyl ethyl ketone, Methyl isobutyl ketone,
Acetone, and Methylene chloride. The physical properties of some of these solvent are
presented in the Appendix A.
1. Water Based
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The water based acrylic area has two blending tanks where specific acrylic paint recipes are
produced. The general ingredients for these types of paints are water, pigment, resin, additives
and biocides (anti fungal/bacterial agents). The pigment is added to the blending tank in a
powder form. To prevent pigment dust emanating throughout the factory, vacuum extraction
units are used. Any residual pigment dispersing out of the blending tank is drawn up into the
extraction unit, which then passes through a number of filters. The filtered residual powder is
collected as solid waste.
After a batch of paint was produced the blending tank and all associated tools used with
that batch (eg. agitator) need to be cleaned. Before the cleaner production initiatives the
blending tanks were cleaned by a low-pressure water rinse technique. All wastewater was
then stored in underground sludge-holding tank. This is the first problem is facing the
Kilanis Paints.
2. Solvent Based
Solvent-based paints contain essentially the same core ingredients as acrylic paints besides
the distinction in base. Solvent-based paints are not susceptible to fungi and bacteria therefore
no biocide is required.
In general, solvent-based paint is produced by mixing chemicals (primarily resins, dry
pigment, and pigment extenders) in a container equipped with a high-speed mixer. Solvents
and drying oils also are added during this step. After mixing, the batch may be transferred to a
millfor additional grinding and mixing. Next, the paint base or concentrate is transferred to a
tank where the tints, thinner (usually a volatile naphtha or blend of solvents), and the balance
of the resin are added and mixed. Upon reaching the proper consistency, the paint is filtered to
remove any non-dispersed pigment and transferred to a loading hopper. From the hopper, the
paint is poured into cans, labelled, packed, and stored in the appropriate location. Figure 1
illustrates the specific production processes for paint production in the plant.
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The blending tank cleaning process is done with a solvent. This is the second problem is
facing the Kilanis Paints.
Solvent required cleaning the mixing and dispensing equipments and tanks between batches is
the major source of solvent waste in the manufacture of solvent-borne paint. Information from
company records and from interviews with key staff was gathered to determine the volume of
wash solvent (mineral spirits) diverted from the waste stream by implementation of the reuse
program at Kilani
The volume of wash solvent diverted from the waste stream could vary from year to year,
depending on the product mix and the annual production. This low-tech system has, however,
produced an appreciable reduction in solvent waste at Kilani. Production figures and
background information collected during site visits to Kilani indicate that Kilani diverted
about 12000 gal of solvents per year.
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Fig. 1. General flow scheme of paint production.
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OUR OBJECTIVES
Depends on the above, our objectives are:
1) Evalute the pollution prevention. Evalute the amount of solvent and water diverted
from the wastestream.
2) Constuct and built up a unit which has a cabability to recover the solvent from
washed-solvent in order to produce a solvent that can be reused for the original
application or a lower grade solvent which can be used for different purposes.
3) Constuct and built up a unit to treat the wastewater in the factory.
4) Evalute the economics. Evalute the costs and cost saving of this pollution preventing
project.
5) And finally evaluet the product quality. Evalute the quality of the paint formulated
with wash solvent to ensure product quality.
To do so, the project will be carried out with the following strategic objectives:
Random choice of cleaning solvent will be replaced by an evaluation process, leading
to a choice of one single solvent for all tank and equipment cleaning;
Manufacturing procedures will be modified to minimize the use of wash solvent and
wastewater.
Create a solvent recovery model to recover weekly batches of such solvent for using
and recycling in the paints applications.
Create a wastewater treatment model.
Evaluate the economic viability
Reduce environmentally harmful
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Kilani paint informs me that they used about 25-30 gal of solvent to clean equipment between
batches of production. As I found in the factory, 0% of the wash solvent is reused or
recovered in paint processes. They disposed all the wash solvent.
I also found that the annual solvent waste as shown in the following table. This information
based on 2008.
Kilani production dataNumber of batches
( estimated)/year
400 batches
Quantity of solvent used to clean
tanks
30 gal.
Solvent required for cleanup only 12000 gal.Solvent reuse/recover Zero gal.Waste reduction Zero
The volume diverted from the waste stream could vary from year to year depending on the
product mix and the annual production. It should be noted that the waste reduction is zero in
Kilani Paint factory.
This wash solvent is labelled and stored in 1 m3 tank for addition back into the same or very
similar paint production with three months.
As first step, we advised the employees at Kilani paint make a conscious effort to minimize
the amount of solvent required for cleaning by techniques such as:
Scraping the mix tanks to remove many paint solids before solvent cleaning.
Minimize cleanup of work areas and equipment by taking care when adding
raw materials and dispending finished batches.
WASTE VOLUME REDUCTION FOR WASTWATER
Our main aims were, to investigate wastewater characteristics, to examine possible treatment
methods, to suggest ways to reduce wastewater production and select the most appropriate
waste minimization options to advice to the Kilani paint factory.
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A Waste Minimization Opportunity Assessment is a systematic procedure for identifying
ways to reduce or eliminate waste water. The assessment consists of a careful review of a
Kilani paint factorys operations and wastewater streams and the selection of specific areas to
assess. After a particular wastewater stream or area is established, a number of options with
the potential to minimize waste are developed.
The main sources of wastewater in Kilani factory is the cleaning wastes such as the cleaning
of the reactors, tank and other equipments. I found that the total amount of discharged
wastewater in the Kilani plant is approximated 10-20 m3/d .Therefore to give treatment of
these amounts of wastewater and to state pollution prevention options appropriate for this
industry; we carried out a laboratory works such as coagulation process and some tests.
SECTION 4
DESCRIPTION OF THE PROCESSES OF WASHED
SOLVENT
I classified the process of washed (or waste) solvent in Kilani factory as follow:
Class one:
I must emphasize that our processes only work because the company employees were
involved from the beginning; the problem and its ramifications was explained to them,
and their cooperation made, and makes, the program work well.
Class two:
Then I went to the second step which is the process. Here we divided the process into
three part processes:
First process (Storage area) :
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In the storage area, I marked the used solvent as groups (for example group 1, group 2
etc). Group 1 is washed solvent from white, group 2 is washed solvent from clear
paint, and group 3 is washed solvent from gray paint and so on.
This process is eliminated the need for substantial volumes of solvents needed for
tank rinsing and flushing after each batch. Then, whenever possible, thesolvents used
for mill wash and filter flushing was either used in that batch or held inmarked drums
for the next batch of the same or similar color. See the Figure below.
Second process (Initial Treatment):
Wash solvents generated in other areas that were not amenable for reuse in the
production process was, and is, collected in others drums/tanks. This material is
allowed to sit and settle undisturbed for several days. High level of suspended solid
may be separated from solvent by sedimentation or gravity settling. At that time, the
clear, thin solvent is decanted from the top of the drum/tank and is used as the first
wash on specified mills, some portable tubs, filling machines, etc. This process of
settling and decanting continues until the material in the drum/tank becomes too thick
or heavy to be usable as a wash solvent. The drum/tank is then labeled and dated as a
hazardous material and set aside for treatment as shown in the third process. See
Figure 3.
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Figure 3: Tanks in Kilani factory
Third process (recovery process):
It is the treatment process. We design and construct a process for solvent recovery.
This process is consisting distillation unit which capable of handling 120 tons per year
of dirty (washed) solvent.
The distilled solvent is, in most cases, about 96-97% pure. Initially, it will be intended
to use the distilled solvent, but even 3-4% dilution significantly reduced cleaning
efficiency. It will be trialed as a partial replacement for purchased solvent in several
blended thinner formulations which Kilani paints will find to be satisfactory in many
of the products. By using the distilled solvent to replace new solvent, it will be easily
converted to a relatively cheap solvent that can be sold.
DESCRIPTIONOFTHE DISTILLATIONPROCESS
As shown in the figure 4:
A. Feed Tank Reservoir. A stainless steel tank with a sloping bottom for proper
drainage
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B. Reboiler. Cylindrical glass with a capacity of, approximately, 3.8 - 4.0 gal at
operating level. The boiler, covered with foam rubber insulating material. The main
heating element is a stainless steel heated bayonet-type 3-phase electric heater with a
nominal power rating of 15 Kilowatts at 240 VAC. The power to the heating elements
is controlled by an electronic switch which operates by cycling the heater on and off in
1 to 3 seconds intervals. The relative times the heaters are on or off determine the
amount of power supplied to the reboiler. The reboiler also has a drainage stop-cock.
C. Column. Consist of sections each assembled from a 3-inch ID glass pipe section.
Each section contains process fittings for feed, pressure and temperature measurement.
The column, when assembled, is approximately 31 inches in height, bolted to the
boiler at its bottom and to the vapor riser at its upper end by means of a bell reducing
coupling section and a flexible Teflon expansion joint.
D. Condenser. A glass shell-and tube type heat exchanger, which contains the
equivalent of 1.3 sq. ft. of spiral-tube heat exchange surface. The tube side coolant is
water from the municipal water supply. Thermocouples are placed in the tube side to
monitor the inlet and outlet temperatures of the cooling water. The spiral condensing
tube is 160 inches long coiled to a length of 18 inches. The tube is 3/8-inch OD, with
0.019-inch wall. The shell side condensate drains through a 3/8-inch line to the
distillate receiver. The cooling water supply to the condensed is equipped with a flow-
switch that will cut the power to the reboiler if there is a loss of water flow to the unit.
E. Feed Pumps. A stainless steel pumps are used for the feed.
F. Distillate Receiver. A 3-inch OD by 12-inch long Pyrex glass tube that is flanged top
and bottom with stainless steel caps. Condensate enters from the condenser through a
3/8-inch tube into the top, which is fitted with a thermocouple. There is a valve drain
at the bottom.
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G. Feed Preheaters. Cartridge-type rated at 1500 Watts at 240 VAC and sealed in a
stainless steel type enclosure. Peheater is controlled from an ONOFF type
temperature controller.
H. Thermocouples. Thermocouples are installed at various locations throughout the
distillation column system. These thermocouples are connected to a digital scale for
monitoring and dataloging. These thermocouples are slow to respond to temperature
changes and record temperatures that are slightly lower than the stream inside the
column. All temperature values are displayed and saved to file in degrees Celcius.
Figure shows a typical continuous distillation column. The washed-solvent (paint and
solvent) mixture is fed to the column at one or more points along the column. liquid
runs down the column due to gravity while the vapour runs up the column. The vapour
is reduced by partial vaporization of the liquid reaching the bottom of the column. The
remaining liquid is withdrawn from the column as bottom product rich in heavy
component. The vapour reaching the top of the column is partially or fully condensed.
PROCEDUREAND METHODOLOGY
A. Distillation Column Start-Up Procedure.
Turn on the cooling water to condenser. Check that water flows to the drain from the cooling
water outlets in the rear of the column . Do not start any operation until cooling water flow
is visible in drains. Note that the reboiler heater will not turn ON unless there is flow in the
cooling water line.
1. Fill the reboiler with washed solvent. To charge the boiler, open the feed bypass ball
valve F-5, (located near the reboiler quick connect port Q-1).
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2. Trace the feed line from the reservoir tank through the feed pump and then connect the
flexible tubing feed line to any desired feed port.
3. Turn the main power switch "on", then the feed pump switch.
4. Observe the liquid level in the boiler.
5. Shut feed pump off when the reboiler is full (drain light turns on)
6. Set proportional power control switch for the boiler to the desired heating rate value to
expedite the start-up. Generally, it is best to turn full power on until boiling begins, then
reduce the power to the desired value.
7. Turn the boiler power switch on; a pilot light should indicate heat input. The System
should heat up and begin boiling in 10 to 15 minutes if full power is applied.
8. While the System is heating up, open the distillate receiver overflow. The distillate drain
valve should be closed.
9. When boiling starts and condensate starts to form in the condenser, turn the feed pump on .
Adjust the feed flow to the desired flow rate.
A. Distillation Column Shut-Down Procedure. (See Figure 4):
1. Turn boiler power switch off.
2. Turn off feed preheater.
3. Turn off feed pump.
4. Shut off cooling water to condenser and pumps.
5. Do not drain the hot paint from the reboiler. The reboiler can only be drained when it is
cool.
RESULTS AND OUTPUT
The amount of solvent recovery by using distillation process is shown in the following table.
Our results based on 4 gal as basis of washed solvent.
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Kilani production dataNumber of batches
( estimated)/year
400 batches
Quantity of solvent used to cleantanks 30 gal.
Solvent required for cleanup only 12000 gal.Solvent reuse/recover
(90%*12000 gal)
10800 gal.
Waste reduction 1200 gal.
It can be observed that the percentage of solvent recovery is
Percentage = 10800/12000= 90%One site sample collection and testing
Different wasted solvent of Toluene after the cleaning of tanks were collected after the
batches of production. The sample was taken at the end of the tank washing. We used the
washed solvent that used in the cleaning of black tanks, which is the difficult one to be
handed. This sample was pumped as the feed of distillation unit. Most the solvent was
vaporized and condensed at the top of the column and paints was collected in bottom of the
boiler as shown in the figure below. The condensed solvent was analysed using gas
chromatography and viscometer. The following results that we obtained:
Property Value ( our results) Literature
Assay 96% 99 %Boiling point 108 C 110 C Density 0.859 g/cm 3 0.862 g/cm3
From our results, we can see that the most of the disposal washed solvent can be recovered
and recycled. Also, on comparing these results with those values of the literature, we see that
a good agreements between them. It means that, even if we use the distillated Toluene
(recovered Toluene) in the production of paints, we expect that the properties of paints will
not be changed.
Also we have to concentrate on the other important point which is the solid waste that
remaining in the boiler after the distillation process. These solid are paint constituents and
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can be reuse it again in the manufacturing of the paints. This part needs more studies and
research. Therefore, I advised the Kilani factory to concentrate on this point in another
studies.
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CondenserDistillate ReceiverReboilerDistillation columnCooling WaterFeed
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Figure 4 : Distillation Column
Condenser
Feed
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SECTION 5
DESCRIPTION OF THE PROCESSES OF
WASTWATER
Water Problem
The major hazardous wastewater sources are process water, cleaning residue mixed with
water, and spills that occur when paint is inadvertently discharged in the production area. The
total amount of discharged water in the plant is approximated 10-20 m3/d. Although this
amount is quite low in comparison to other industries, the cost of treating and disposing of
this wastewater is significant.
White paint washings currently constitutes over 50% of wastewater produced during
cleaning operations. The other 50% comes in the form of other colours wash water. These
other colours washings are also discharged into other tanks. See Figure 5.
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Figure 5. Washing tank by water
DESCRIPTION OF THE PROCESS
In this part we used a simple process to treat the wastewater which is called coagulation
process.
COAGULATIONPROCESS
Coagulation and flocculation processes are an important part of water and waste water
treatment. The processes of coagulation and flocculation are employed to separate suspended
solids from water. The particles are essentially coated with a chemically sticky layer that
allows them to flocculate and settle in a reasonable period of time.
In wastewater of paint, in general, coagulation precedes chemical or biological processes
which are pre-treatment for the removal of suspended solids, foam and high molecular weight
compounds. Coagulation is also used for the removal of turbidity , water clarification
and organic load abatement (COD , BOD).
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Destabilization of a colloidal suspension results in joining of minute particles by
physical and chemical processes which presented by neutralizing the forces that keep the
colloids apart. Cationic coagulants provide positive electric charges to reduce the negative
charge (zeta potential) of the colloids. When the coagulant added to the water numerous
species of hydroxyl metallic complexes are formed because the complexes, which are
hydrolysis products.
Wastewater Samples
Wastewater samples are collected from the discharges of Kilani paint factory. The wastewater
is mainly characterized by its color variation and high load of Chemical Oxygen Demand
(COD). The characteristics of the raw wastewater (RW) are as shown in the table below
Parameter concentration
pH 7.35Conductivity, ms/cm 2.35Turbidity (NTU) 26.98COD, mg/l 9600BOD, mg/l 16324Total phosphorus, mg/l 7.52Chloride, mg/l 266Sulphate, mg/l 2389
Methodology and Procedure
In this part, we carried out the work based on the lab scale. Four equal-volume beakers are
used; 500 ml of paint wastewaters was taken in a 1000 ml worked volume beaker and, after
addition of coagulant aid, mixed for 5 min at 150 rpm to insure complete dispersion. See
figure 6.
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Color measurement: Prior to color measurement, the sample is filtered through
a membrane filter (0.45m) to prevent turbidity. Color measurements are
carried out with a spectrophotometer.
Since the wastewater contains different kinds of pigments (depending on the
production), the traditional method of applying the maximum absorbance is not
used. Color content is determined using a UVvis (Model 7800UVvis
spectrophotometer) by measuring the absorbance at three wavelengths (436,
540 and 660 nm) and taking the sum of these absorbencies.
Amount of sludge: The volume of decanted sludge is estimate by the
volumetric method using the graduated cylindrical. Once the experiment has
been performed, the beaker contents are transferred to special graduated
cylindrical. After 1 h of settling, the sludge production is determined by direct
reading as ml of sludge/l of wastewater treated.
RESULTS AND OUTPUT
Treatment efficiency is evaluated in term of the recovery of treated water and pollutant
removals (turbidity, COD and color) as well as in terms of sludge production. We determined
the optimal operating conditions as follow:
The percentage of the recovery was calculated based on the amount of wastewater
used and the amount of water treated. About 425 ml was recovered, therefore
Percentage recovery = 425/500
= 85 %
The pH solution is an important factor in the coagulation process. The use of
coagulant at its optimum pH displays maximum pollutant removal. To optimize the
pH of the coagulation process, a known volume of prepared coagulant aid solution is
added to 500 ml of wastewater at different pH value adjusted with concentrated
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H2SO4 and NaOH. The mass of coagulant aid was 600 mg/l. I found that the turbidity
removal is most effective at a pH range between 8 and 9. See figure 7
I also studied the effect of the coagulant aid dosage on the COD and
color removal by varying the amount of coagulant in the paint
wastewater, while keeping other conditions constant (pH 8.5). I
observed that for the quantitative removal of 82% of COD and 94%
of colorings matter, a minimum dosage of 600 mg/l of coagulant aid
is required. I also observed that a further increase in the coagulant
dosage does not produce better removal rate.
Amount of sludge was estimated by graduated cylinder as shown in Figure 8. I found
that the volume of the sludge production is 50 ml.
I also optimized the cost of the paint wastewater treatment; I found that the operating
cost of 1 m3 is 0.15 JD
The remaining solid waste after the coagulation process is mainly paintcomposition. We suggest that these wastes must to be studied and reused in thepaint production
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Figure 7: pH readings
Figure 8: Treated water and sludge
the summary of an interesting point. You can position the text box anywhere in the document. Use the Text Box Tools tab to change the form
Sludge production
reated water
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SECTION 6
ECONOMIC EVALUTION
The objective of economic estimation is to locate a payback period and cost reduction
associated with implementation of this technology for reducing the solvent waste stream and
paint wastewater. Economic estimations for evaluating the technology are based on capital
and operating costs.
CAPITAL COSTS FOR WASH-SOLVENT REUSE SYSTEM
The wash solvent reuse system used by Kilani Paint did not have significant capital cost. No
equipments were purchased, no addition storage area was need, and addition energy supply
was needed. Total expenditure to implement the system is estimated by us to be less $2000
($1500 +$500).
OPERATING COSTS
The major operating costs associated with the washed solvent reuse system are shown in the
table below. It can be seen that the labour cost are the same weather wash solvent is disposed
of or stored for reuse. The washed solvent must be collected in tanks in both cases. Electricity
is required and it is considered within the operating costs.
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I. Washed solvent (Toluene)
CAPITAL
COST
$1500
OPERATING
COST
Cost item Annualamount
Unitcost
Annualcost
Solvent waste disposal 12000 gal $
2/gal
$ 24000
Total without reuse $ 24000
Solvent not reused 1200 gal $
2/gal
$ 2400
Electricity $1600
Total with reuse $ 2400
Annual saving of
wash solvent
$20000
II. Wastewater
CAPITAL
COST
$500 JD
OPERATING
COST
Cost item Annual
amount
Unit
cost
Annual
cost
Waste water disposal 6000 m3 $1/m3 $ 6000
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Coagulant aids $ 0.2 $0.2/
m3
$1200
Total $ 6200
Treated water
(6000*85%)
5100 m3 $1/m3 $5100
Annual saving $4000
Economic Evaluation of Washed Solvent
A simple payback period calculation for this project evaluation can be performed with the
capital cost and operation costs. The cost saving in this system comes from the reduction of
disposal charges and the reduction of solvent purchases.
Payback=capital costs/ saving in annual operating costs
Capital costs for solvent recovery in Kilani paints including material, labour and others simple
equipments are $1500. The total operating saving are $ 21600, this include saving on both
waste disposal and material purchased based on the 2008. Operating costs are affected by
reducing the volume of new solvent purchased. Because solvent prices fluctuates with the
market and the volume purchased, these saving vary somewhat.
The recovery of 10800 gal of wash solvent for reuse in paint manufacturing reduces solvent
raw material purchased by that amount. Based on the cost of $ 2 per gal for solvent, this
represents a saving of about 21600$.
The payback period of implantation of the wash solvent recovery system at Kilani paint was
approximate one month.
Payback=1500/21600= 1 month
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Inlet Washed SolventEvaporator
SECTION 8
SUSTAINABILITY STUDY FOR SOLVENT RECOVERY
Depend on our results as created in the small scale process, we (The owner of Kilani and I)
decided to go to industrial scales or large scales to recover the solvents. To do that, we bought
some equipment; these equipments are consists of evaporator, heat exchanger, vessel, pumps
and pipes as shown in the following figures:
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Outlet of sludge
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Heat ExchangerCover of Heat Exchanger
This part is already built in the Kilani Paint Factory for few days ago. We
are now in running way to collect others parts like vessels, heat
exchangers, pumps and with its pipings. See the following Figures.
Vessel
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We expect that the installation of all parts will befinished by the end of the Dec 2009, while theoperation process will be started at thebeginning of Jan 2010.
Methodology
The feed of washed solvent will be pumped from the vessel to the pointof feed in the evaporator.
The washed solvent will be heated using an external heating thatwrapped around the evaporator.
The vapour of solvent will be condensed by the heat exchanger. The sludge of washed solvent will be drained at the bottom of
evaporator.
SECTION 9
APPENDICES
Appendix A: Physical properties of solvents
Toluene
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Property value
Molecular weight 92.14
Boiling point 110.62C
Vapor pressure 28.5 Torr at 20C
Freezing point -94.99C
Refractive index 1.4969 at 20C
Density 0.8623 g/mL (7.196 lb/gal) at 25C
Xylene
Property value
Molecular weight 106.167
Boiling point 144.41 C
Vapor pressure 0.7 Kpa at 20C
Freezing point -25.182 C
Refractive index 1.5054 at 20C
Density 0.8802, g/cm3 at 25C
Appendix B: Approvals and Acceptance letter of the project
output
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Appendix C: Poster
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Appendix D: Faculty and Factory surveys
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