INNOVATIVE AND COST EFFECTIVE ZERO LIQUID DISCHARGE ZERO LIQUID DISCHARGE TECHNOLOGY FOR INDUSTRYTECHNOLOGY FOR INDUSTRY
Leif Ramm-Schmidt, Ramm-Schmidt Consulting Ltd, Finlandrepresenting Arvind Envisol Private Limited Ahmedabad Indiarepresenting Arvind Envisol Private Limited, Ahmedabad, IndiaPresented at: Seminar and Training Workshop on Zero Liquid Discharge, Ahmedabad 27th January 2014
WORD TRENDS
• Environmental pressure from population growth• Environmental pressure from population growth• Clean water reservoirs steadily diminishing• Growing demand for all kinds of water purification• Growing demand for all kinds of water purification• In industry in particular:
Water recovery– Water recovery– Closing of water loops
N t h l• New technology:– Low cost corrosion resistant polymeric heat
exchangersexchangers– To be used in highly efficient evaporation
technology
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technology
POLLUTION OF RIVERS AND WATERS
Man made eutrophication
Industry plays a majorrole
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POLLUTION OF RIVERS AND WATERS
Death of ecosystem,y ,diseases spread, no source for drinking waterwater......
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WHY IS ZERO DISCHARGE NEEDED IN INDUSTRY ?
• Industry uses huge volumes of pure water d i j ll t f tand is a major polluter of water courses
• Conventional effluent treatment does not remove pollutants sufficiently nutrients andremove pollutants sufficiently – nutrients and salts are not well separated
Typically:
ZZ di hdi h f tf tZero Zero discharge discharge rere--use of wateruse of water
Leaving the clean water for human consumption - with great improvement in standard of living
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Applicability of different water treatment technologies
3 = high separation 2 = moderate 1 = low separationNote! pH may change rating considerably
Pollutant to remove
Dissolved substances
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TechnologyAdsorption (e.g. activated carbon) 1 1 1 1 1 1 1 3 3 3 1Ion exchange 3 3 3 3 2Chemical precipitation 1 2 3 2 2 1
Methods have often to be
bi d Chemical precipitation 1 2 3 2 2 1Membrane technologies Ultrafiltration (UF) 2 1 1 Nanofiltration (NF) 2 3 2 2 3 2 3 2 Reverse osmosis (RO) 3 3 3 3 3 1 3 3 1 3 3 3 Electrodialysis 3 3 3 3 3 3
combined for zero discharge operation
Evaporation 3 3 3 3 3 2 3 3 3 3 3Distillation 3 3 3Flotation 1 1 2 2 2 1 1Air/steam stripping 3 2 3 2Electrical methods
El t l 3 3 3
por to meet discharge limits
Electrolyse 3 3 3 Electro coagulation 1 3 3 2 2 2 2Biological treatment 1 1 2 1 1 2 3 3 3 1 2 1 2
TREATMENT TECHNOLOGIES
7SIMPLE AERATION, WATER RE-USE NOT POSSIBLE
FILTRATION SPECTRUM OF SEPARATION METHODS
EVAPORATION
NANO-
REVERSE-
OSMOSIS Evaporation and RO are only
MICROFILTRATION
ULTRA-
FILTRATION
FILTRATION technologies that remove dissolved salts
PARTICLE FILTRATION
MICROFLOTATION
MICROFILTRATION
0 01 0 1 1 10 100 10000 001
PARTICLE FILTRATION
PARTICLE SIZE IN MICROMETERS
IONIC RANGE
0,01 0,1 1 10 100 10000,001
MACRO MOLECULAR
RANGE
MICRON
PARTICLE
FINE
PARTICLE
COARSE
PARTICLE
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RANGE RANGE RANGE
SALT AND COD REMOVAL EFFICIENCIES IN A SALT AND COD REMOVAL EFFICIENCIES IN A PAPER INDUSTRY EFFLUENT STREAM
PARTICLE FILTRATIONPARTICLE FILTRATION
MICROFILTRATION
MICROFLOTATION
MICROFILTRATION
MICROFLOTATION
COD
NANOFILTRATION
ULTRAFILTRATION
NANOFILTRATION
ULTRAFILTRATIONSalts
EVAPORATION
REVERSE OSMOSIS
EVAPORATION
REVERSE OSMOSIS
EVAPORATION
0 10 20 30 40 50 60 70 80 90 100
Removal efficiency %
EVAPORATION
Removal efficiency %
PRIMARY RULE IN ZERO DISCHARGEPRIMARY RULE IN ZERO DISCHARGE
• Zero discharge with water re-cycle will work only if y yall pollutants and salts are almost 100% removed.
• If not, accumulation of ,COD and salts in the process will take place!p p
Evaporation and RO are only technologies that remove dissolved salts
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remove dissolved salts
EVAPORATION - THE METHOD TO ACCOMPLISH TOTALLY CLOSED WATER LOOPTOTALLY CLOSED WATER LOOP
PROCESSPROCESSMAKE-UP WATER
PROCESSPROCESS
WASTE WATERWASTE WATERFRESH WATERFRESH WATER
To public sewer• To public sewer• Treated locally to meet
discharge limitsDi h d
Internal measures taken to use water efficientl • Discharged to natureefficiently
PURGED SOLIDS
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EVAPORATIONEVAPORATION
WHY EVAPORATION ?
From a technological point of view evaporation is an ideal method for purification of industrial peffluents, process waters and landfill leachates for the following reasons:
• All non-volatile substances can be completely completely separatedseparated
• Water recovered from the effluent stream is of high qualityhigh quality
• Evaporated water (distillate) can, as such, in most cases be reusedreused in process or discharged into the
tnature• Harmful solids can be concentratedconcentrated to a
manageable amount for appropriate disposal
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manageable amount for appropriate disposal• Valuable solids can be recoveredrecovered and reused
WHY NOT YET ? - DRAWBACKS OF WHY NOT YET ? DRAWBACKS OF CONVENTIONAL EVAPORATION SYSTEMS
High operational costs (high energy consumption)
High capital costs especially when corrosive streams (high chloride content low pH etc ) arestreams (high chloride content, low pH etc.) are treated; noble materials high costs
Problems with scaling and fouling -irreversible and difficult to control especially with waste waters having varying qualitywith waste waters having varying quality
Steam and cooling water requirement of steam
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g qoperated evaporator (ME, TVR) systems
4-EFFECT EVAPORATION4-EFFECT EVAPORATION
CoolingSpecific Steam Consumption = 0,28
CoolingWaterCONDENSER
Vapour
VapourFeed Vapour Vapour
Vapour
SteamVapour
Waste Heat
Concentrate
CondensatePrimary Condensate
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MVR EVAPORATIONMVR EVAPORATIONP = C x MF x DTP = Fan Power Use (kW)C C (2 5 3)COMPRESSOR C = Constant (2,5…3)MF = Vapor mass flow (ton/h)DT = Temp. difference (°C)
COMPRESSOR
VapourCompressedVapour
DT Steam consumption ~ 0
Cooling water cons ~ 0
Feed
p Cooling water cons. ~ 0
Concentrate
Condensate
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NEW EVAPORATION TECHNOLOGYNEW EVAPORATION TECHNOLOGY
USING LOW COST POLYMERIC FILMS AS HEAT TRANSFER AREA
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NEW POLYMERIC FILM EVAPORATION TECHNOLOGY 1
Q = U x A x DT Low cost Evaporative surface o large heat transfer surfaceo small temperature difference
Q = U x A x DTPFan = C x MF x DT
o small temperature differenceo low energy use - typically 8 to 14 kWh per m3 of
purified water (MVR)
Efficient production of polymeric heat exchangerl b helements by new machine
(1,5 million m2/year)
C t l f ti f Costs only a fraction of metallic ones
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COST OF SOME HEAT EXCHANGER MATERIALSCOST OF SOME HEAT EXCHANGER MATERIALS
M i l R l i / 2Material Relative cost/m2
AISI 316 51 x 1 0 mm tube (50 EUR/m2) 1 AISI 316 51 x 1,0 mm tube (50 EUR/m2) 1 254 SMO 51 x 1,25 mm tube 2,5 654 SMO 51 x 1,25 mm tube 4,9 Sanicro 28 51 x 1,8 mm tube 5,7 Hastelloy C276 51 x 1,0 mm tube 13
Tit i 50 8 0 9 t b 13 Titanium 50,8 x 0,9 mm tube 13
Polyolefin film 40 my (0 3 EUR/m2) 0 006 Polyolefin film 40 my (0,3 EUR/m ) 0,006 High tech plastic film 0,06
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NEW POLYMERIC FILM EVAPORATION TECHNOLOGY 2
Polymeric surface Polymeric surface corrosion resistant less scaling flexible - easy cleaningflexible easy cleaning
Mechanical Vapor RecompressionPrinciple (MVR) minim l st m r c lin minimal steam or cooling
water required
Simplified Vapor Compressor p p p(Fan) Design low operating speeds reliable easy maintenance
Also multi-effect (ME) systems using waste heat or solar
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POLYMERIC EVAPORATIVE HEAT EXCHANGERCARTRIDGECARTRIDGE
The heart ofheart of the system
50 elements50 elements
Surface area 200 m2
Total weight 50 kgTotal weight 50 kg
MVR EVAPORATOR - OPERATIONMVR EVAPORATOR OPERATION
Low speed vapori fFan blower as vapor compressor
Compressed vaporImpellerVacuumvessel
compression fan
Condensati oninner surface
Fan blower as vapor compressor
por
et
inner surfaceFalling filmevaporatio nouter surface
Va inle
Vacuu mpump
Condensa teCirculationwater
Condensate tank
Feed efflue nt
Concentrate
water
Polymeric Cartridges
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y g
MVR EVAPORATOR - OPERATION
Effluent distribution
Vapor to fan
BatteryofP l iPolymericCartridges
Distillate outlet
Circulating effluent
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Circulating effluent
MULTI EFFECT (ME)MULTI EFFECT (ME)
When waste/surplus heat is available the Multi EffectWhen waste/surplus heat is available the Multi-Effect (ME) Concept becomes feasibleBenefits of the Polymeric Film concept in the MEBenefits of the Polymeric Film concept in the ME process:
Very large surface available at reasonable cost Very large surface available at reasonable cost
Low temperature difference over each effect -ff t d l it ith imore effects and larger capacity with a given
energy amount
Effi i t tili ti f t h t i f f h t Efficient utilization of waste heat in form of hot liquid, vapor or gas
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MULTI EFFECT (ME) - OPERATION( )
6 Effects
Hot fi ltrate 85 °CFlashcoo ler
Vapor 65 ° C T = 19°C
CONDENSER
40 °C
Cooled filtrate 65 °C
Fresh /processwater
25 °C
VAPO
R
VAPO
R
VAPO
R
VAPO
R
VAPO
R
VAPO
R
1. Effect 2. Effect 3. Effect 4. Effect 5. Effect 6. Effect
Condensate
25 C
65 / 63 °C 63 / 61 °C 61 / 58 °C 58 / 55 °C 55 / 51 °C 51 / 46 °C Concentrate
FEED EFFLUENT
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MULTI EFFECT EVAPORATION USING WASTEHEATHEAT
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SOLAR POWERED ME EVAPORATOR
Boiler5 MW
Boiler for back up
90˚CSOLAR POWERED ME EVAPORATOR -
SIMPLIFIED FLOW DIAGRAMSolar
Collectors
Vapor 65Cº
Collectors24.000
m21.000 m3/d clean water
Condenser
6-Effect ME Falling Film Evaporator
40ºC
FlashCooler
250 m3/h
1. Effect 2. Effect 3. Effect Cooling water
Condensate
30ºC4. Effect 5. Effect 6. Effect
Tank
Concentrate
65/63ºC 51/46ºC55/51ºC58/55ºC61/58ºC63/61ºC
80ºC55ºC
2000 m3 42 m3/h
90ºC
45ºC Feed118 m3/h
118 m3/h
42 m3/h
4,7 MW
45 C
1 MW of solar heat produces appr. 9 m3/h of clean water84 m3/h
COST SAVINGS IN WATER RECYCLING BY COST SAVINGS IN WATER RECYCLING BY EVAPORATION
Fresh water cost savings, including possible cleaning costs
Reduced or no cost for conventional effluent treatment
N f l d h dli No cost for sludge handling
Cost savings in land allocated for conventional treatment
Value of recovered solids (positive or negative)
Heating of the water to the process temperature
With new technology: The savings can be bigger than the operation costs!
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With new technology: The savings can be bigger than the operation costs!
TYPICAL EVAPORATOR LAY OUT (14 CARTRIDGES)TYPICAL EVAPORATOR LAY OUT (14 CARTRIDGES)
Large diameter unit (3,8 m)Large diameter unit (3,8 m)
CONTAINER SIZE EVAPORATOR (10 CARTRIDGES)
Small diameter unit 2,4 m
MVR-FANMVR FAN
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TYPICAL APPLICATION AREASTYPICAL APPLICATION AREAS
Textile industry Textile industry Steel and metal industry Mining industry Mining industry Pulp & Paper Food and feed industry Landfill leachate Groundwater remediation Seawater desalination Seawater desalination Chemical industry Electronic industryE y Power plants Pharma industry
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REFERENCE PLANTSREFERENCE PLANTS
More than 40 plants already operating in India and Gujarat some 20 other plants India and Gujarat, some 20 other plants elsewhere in the world........
Some examples.....p
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TEXTILE WASTE WATER 3 X 500 M3/D
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METAL INDUSTRY WASTE WATER 200 M3/D
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COPPER ROD MANUFACTURING RINSING WATER TREATMENT – DILUTE SULFURIC ACIDTREATMENT – DILUTE SULFURIC ACID
Pickling
Copper Rod
Protection BasinRinsing
H SO2 4 Surfactant
Vapor
Recovery ofWater
Condensate
Concentrate Electro-
Evaporator360 / 24L-1.2
Copper
AcidComment by owner:"The low energy consumption is
Steam
Boiler Stripper
winning Coppergy pspectacular and real. Thanks to this system, we've decreased overall factory energy consumption, while increasing
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CuAcidour production rate and our product quality."
RO & EVAPORATION – PRIMARY TECHNICAL RO & EVAPORATION PRIMARY TECHNICAL DIFFERENCES
RO no fouling allowed! low final concentration
Evaporation fouling (scaling) can mostly be handled high final concentration low final concentration
very good pretreatment needed salt separation 95 – 98%
high final concentration only coarse pretreatment needed, if any salt separation > 99,9%
limited pH & temperature if leaking -> to clean water electricity powered
no pH & temperature limits if leaking -> to dirty water steam & waste heat or electr. powered electricity powered
lower investment cost steam & waste heat or electr. powered higher investment cost
RO + Evaporation may be a good combination, but evaporation alone provides often the simplest solution!
POLYMERIC FILM EVAPORATION COST COMPARISON TO POLYMERIC FILM EVAPORATION COST COMPARISON TO CONVENTIONAL EVAPORATION (”LARGE EVAPORATORS”)
Energy consumption (el = 6 Rs/kWh, steam 1 Rs/kg) Rs/m3 clean water
New technology MVR (12 kWh/m3 + 10 kg steam/m3) 82 Conventional MVR (25 kWh/m3 + 20 kg steam/m3) 170 Conventional ME 1 stage (2 kWh/m3 +1100 kg steam/m3) 1112 Conventional ME 1 stage (2 kWh/m3 +1100 kg steam/m3) 1112 Conventional ME 4 stage (3 kWh/m3 + 280 kg steam/m3) 298
Relative investment cost Relative Low corrosion (incl. sea water) 0,7 – 0,9
M di i 0 6 0 8 Medium corrosion 0,6 – 0,8 High corrosion (high chloride, acids) 0,4 – 0,5
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CONCLUSIONSCONCLUSIONS
Evaporation in general: Almost only tool for zero discharge systems Evaporation is the most powerful tool for removal of dissolved pollutants (salts, organic matter etc.)
But costs are high in conventional evaporators MVR reduces operation costs Scaling and fouling may be a problem
New Polymeric Film technology: Investment and operation costs are considerably Investment and operation costs are considerably
reduced Scaling and fouling problems are more easily managed
R li f i i l dil ffl i Recycling of surprisingly dilute effluent streams is becoming feasible
Waste heat or solar can be efficiently utilized (ME) y
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ADDITIONAL INFORMATIONADDITIONAL INFORMATION
Leif Ramm-Schmidt, Ramm-Schmidt Consulting [email protected]
Chandan Kumar, Arvind Envisol Pvt. Limited Limited [email protected]
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