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16-7-2012
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16/07/2012
Cross-sectoral synergies in industrial water use
Joost Helsen
i-SUP conference
Bruges 7th-9th May 2012
16/07/2012 2© 2012, VITO NV
Outline
� Goals
� General approach to optimize waternetworks
� State-of-the art in the four sectors
� Synergies between sectors
� General water management
� Closing water loops: technologies
� Monitoring
� Overview in relation to general water network
� Road for the future
HJ1
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16/07/2012 3© 2012, VITO NV
Goals
» General objective AquaFit4Use:
Development of new reliable cost-effective
technologies, tools and methods for
sustainable water supply, use and discharge
in paper, chemical, food and textile
» Specific objective:
Determine cross-sectoral benefits for
sustainable water loop closure
Sustainablewater use
Paper
Textile
Food
Chemical
16/07/2012 4© 2012, VITO NV
General approach to optimize water networks
» Inventory
» Processes, water sources, water treatments,…
» Water network visualization
» Water quality definition (WQD)
» Which WQ is needed for which process?
» Effects on :
» Product safety/quality
» Process water function
» Equipment, machinery and pipes
» Health and working conditions
» Evaluate mass balances:
» Measure water flows
» Monitor process effluents quality
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16/07/2012 5© 2012, VITO NV
General approach to optimize water networks
» Simulation of (parts of) water network to:
» Calculate/estimate missing data
» Evaluate effect of changes in water
quality
» Optimization of water network based on:
» Costs
» Fresh water use
» Discharge volume
» Evaluate optimised water networks:
» Lab-scale and pilot trials
» Environmental impact
» In depth economical analysis
Pinch
Sinks
Sources
Fresh WaterRe-Use
Waste Water
Reactor
Cyclone
Cooling
towerSteam Filter
Reactor
Cyclone
Cooling
towerSteam Filter
16/07/2012 6© 2012, VITO NV
Paper sector at a glance
» Quite uniform production processes
» Typically 2 continuous systems :
» Stock preparation
» Paper machine (fresh water)
» Re-use implemented on different levels:
» Direct in PM and SP
» process effluent recycle
» Recycle treated waste water
» Threats for recycling water:
» recalcitrant COD (‘slime’ formation, product quality)
» High Ca/Si levels (scaling)
» high Cl-levels (corrosion)
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ETP
Fresh water
Raw material
Paper
SP
PM
K1= CODeff
CODWW1
K2= CODSP
CODWW1
COD (filtrated sample)
K1/K2= CODeff
CODSP
Fresh water use
Loop separation
Counter current arrangement
ETPWWTP
Fresh water
Raw material
Paper
SPSP
PMPM
K1= CODeff
CODWW1
K1= CODeff
CODWW1
K1= COD
COD
K2= CODSP
CODWW1
K2= CODSP
CODWW1
K2= COD
COD
COD (filtrated sample)
K1/K2= CODeff
CODSP
K1/K2= CODeff
CODSP
Fresh water use
Loop separation
Counter current arrangement
Paper sector at a glance
» Highly optimized waternetworks
» High content of dissolved matter in water
loops of SP and PM
» Optimization approach:
» Water balance
» Evaluation of K-values
» Process simulation
» Bottle necks:
» Impact water on product quality
» ‘slime’ formation
» odour control
» discharge limits
» Ca-levels (recycling water)
16/07/2012 8© 2012, VITO NV
Chemical sector at a glance
» Typical processes:
» Continuous and batch
» Very complex sequence of unit processes
» Specific contaminants for eachcompany/process
» Common elements: utilities
» Process water treatment
» Cooling water /steam production
» WWTP
» Main water consumers:
» Cooling towers
» Steam production
» Direct water re-use often implemented
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16/07/2012 9© 2012, VITO NV
Chemical sector at a glance
» Optimization strategy:
» Water balance
» Water pinch
» Process simulation
» Bottle necks:
» Salts and organics
» Reagents,by-products, catalysts
» Temperature
» Geographical limits
1,4km
16/07/2012 10© 2012, VITO NV
Food sector at a glance
» Very specific processes depending on type of food production:
milk, vegetables, cheese,…
» Drinking water quality in all processes where contact with food
is possible
» Fluid food processing:
» Pasteurization/sterilization
» Tank storage
» CIP
» Filling lines
» Vegetable processing
» Washing
» Scalding
» Blanching
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16/07/2012 11© 2012, VITO NV
Food sector at a glance
» Optimization strategy:
» Inventory of all water consuming processes
» Monitoring of water flow and contamination levels
» Reduce fresh water usage in-process (e.g. vacuum pumps)
» Minimize product losses (e.g. CIP, sterilization)
» Recycle water to non-hygienic processes (e.g. cooling towers, truck
washing)
» Bottlenecks:
» Stringent demand to use potable water
» Re-use options limited to non-critical processes (e.g. cooling towers,
transport washing, toilets,…)
16/07/2012 12© 2012, VITO NV
Textile sector at a glance
» Water source: mostly ground- or
surface water
» Typical processes:
» many batch processes
» Preparation-dyeing-printing –
finishing
» Process water treatment:
» Sand filtration
» De-ironing
» softening
» Most processes are very water-
intensive due to subsequent washing
and rinsing steps
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Textile sector at a glance
» Critical parameters:
» pH
» Salts, metals
» Suspended solids
» Organics
» Colour
» Optimization of water network:
» Virtually no re-use or recycling of water
» Potential water loop narrowing via separation and treatment of
process effluents
» Main bottleneck:
» Cheap water source vs. expensive water treatment
16/07/2012 14© 2012, VITO NV
Cross sector - watermanagement
» Paper sector introduced new way of thinking:
» Dealing with highly concentrated process streams
» Intensive water re-use with little treatment
» Concept of HACCP applied in process water control:
» Determines CCP’s in industrial water loops
» WQMT or “West for Industry”: integrated, fully customizable tool to
» Define water quality demands
» Visualize and calculate water networks
» Optimize water networks in all sectors
Including a comprehensive WQ-database and model library
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16/07/2012 15© 2012, VITO NV
Cross sector – technological aspects
» Principles of hygienic design valuable for chemical processing and textile
industry to minimize:
» Water needed for washing, rinsing, cleaning activities
» contamination of waste waters
» product losses
» Cross-contamination
» Alternative CIP technologies can be transferred to chemical sector:
» (Ice) pigging
» Air swirling
» Air scouring
» Ice blasting
16/07/2012 16© 2012, VITO NV
Cross sector – technological aspects
» Treatment technologies for removing contaminants in recycled water:
» 3FM
» MBR
» Anaerobic treatment
» Denutritor
» AOP (Ozone, UV,
» NF/RO
» Evapoconcentration
» Softening (crystallization)
» FTC (CapDI)
» …
Tested and applied in all four sectors to produce water “fit for use”
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16/07/2012 17© 2012, VITO NV
Cross sector – monitoring water network
Tools for monitoring water networks and treatments:
» VIT-kit:
» fast and easy detection and quantification of specific target organisms
» VFM sensor:
» On-line measurement of reversible and irreversible fouling in MBR
» FBRM: focused beam reflectance measurement :
» Fast analysis of concentration and size of particles in a solution
» On-line sensors for:
» COD
» Total nitrogen
» Orhophosphate
» Calcium
» WEA for determining real ecological impact of final effluent
16/07/2012 18© 2012, VITO NV
Cross sector – overview
WQMT LCA Water FootprintWQMT LCA Water Footprint
WQcontrolWQcontrol
Treatment technologiesTreatment technologies
WEAWEA
Process
optimization
Local loop treatment
Monitoring VIT/VFM/FBRM/…Monitoring VIT/VFM/FBRM/…
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16/07/2012 19© 2012, VITO NV
Road for the future
» Some ideas:
» Stepping across the company border: creating water loop interfaces
and synergies:
» in industry
» with urban & agricultural water management
» Overcome the bottleneck in recycling and reuse:
Treating concentrates/complex wastewaters
» Linking water- and production processes for process efficiency
optimization
16/07/2012 20© 2012, VITO NV
Acknowledgement
Results were obtained in the project “AquaFit4use” (EU-FP7-ENV-211534)
funded by the European Commission.