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Reuse Wastewater Generated by the Paint and Textile Manufacturing Industries in the Manufacture of Cement Bricks and Tiles:

Case Studies from Egypt

Alabama Water resources Conference; Orange Beach, Alabama, September 5 - 7, 2012

Dr. Robert W. Peters.

Professor of Environmental Engineering

University of Alabama at Birmingham, Birmingham, Alabama

Eng.Mohamed Khaled Elsayed Mostafa

Ph.D. Graduate Student

University of Alabama at Birmingham, Birmingham, Alabama

by

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Statement of scientific or technical problem

Overview

Introduction

Primary objective of the research

Reusing wastewater

Conclusion

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Statement of scientific or technical problem

1- Discharge of industrial effluents into surface water body without prior treatment;

2- The use of old technologies and non-biodegradable substances in industrial processes;

● Poor quality of surface water in Egypt

►Some factors impacting this problem:

(Source: www.inmagine.com, 2011)

Mediterranean Sea

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Introduction

(Source: National Research Centre, 2007 )

0

50

100

150

200

250

Chemicals Food Textiles Engineering Mining Metal sectors Other

Amou

nt (M

m3 /

yr)

Industrial Sector

Amount of wastewater produced from various industrial sectors

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Introduction

0

50

100

150

200

250

300

350

400

450

BOD COD Oil and Grease TDS Heavy Metals

Lo

ad

(t/

d)

Contaminant

(Source: National Research Centre, 2007)

The loads of the most common contaminants contained within sewage

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Primary objective of the research

● Study potential reuse of wastewater generated by the paint and textile manufacturing industries.

DYEING PRINTING FINISHINGPRE-TREATMENT

DYE WASTEWATER

Paint industry

Textile industry

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ParameterResults (ppm)

ParameterResults (ppm)

Cadmium (Cd) < 0.01 Magnesium (Mg) 5.0Cobalt (Co) 0.03 Sodium (Na) 25.6Nickel (Ni) < 0.01 Potassium (K) 0.3Lead (Pb) < 0.01 Chlorine (Cl) 22.5

Iron (Fe) 0.01Total Dissolved Solids

(TDS)4,576

Zinc (Zn) 0.05 PH (unitless) 9.58

Manganese (Mn) 0.04 Phosphor (p) 0.56

Copper (Cu) 0.07 Calcium (Ca) 11.5

Nitrogen (N) 29.4

Analysis of a typical paint wastewater sample

Reusing wastewater

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Analysis of a typical dye wastewater sample

Reusing wastewater (cont’d)

ParameterResults (mg/l)

ParameterResults (mg/l)

Total Dissolved Solids (TDS)

18,165 Chlorine (Cl) 13,270

Total Suspended Solids (TSS)

1,572 Oil and grease 37.6

Chemical Oxygen Demand (COD)

943.0 Total Phosphate 5.2

Biological Oxygen Demand (BOD)

203.0 Organic nitrogen 21.0

PH (unitless) 10.12 Nitrate (NO3-) 5.0

Sulphur trioxide (SO3) 311.0 Nitrite (NO2-) 20 .0

Ammonia (NH3) 6.8

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Reusing wastewater (cont’d)

Statistical Market Forecast for Concrete Blocks and Tiles in Egypt

(Source: Gobi International, 2009 )

2005 2006 2007 2008 2009 2010 2011 2012 2013 20140

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10

15

20

25

30

Year

US

Dol

lars

mil

lion

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Cement bricks

Mix proportions of the cement bricks

Reusing wastewater (cont’d)

Brick: 25*12*6 cm

Raw Material/Mixture No.

A (Clean water)

B (Paint WW)

C (Dye WW)

Coarse aggregate (m3) 0.9 0.9 0.9

Clean water (L) 288 N/A N/A Wastewater (L) N/A 288 225

Cement (kg) 400 400 400Fine aggregate (m3) 0.9 0.9 0.9

BVF (kg) 1.2 1.2 1.2

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● Compressive Strength: (Sample: 25*12*6 cm)

► Minimum compressive strength value specified in ASTM C 55-06 equal 13.8 Mpa (140 kg/cm2).

Reusing wastewater (cont’d)

Mix Sample Number Max. Stress (kg/cm²)  1 175

A (Clean water) 2 170  3 181  Average 175  1 172

B (Paint wastewater) 2 176  3 166  Average 171  1 168

C (Dye wastewater) 2 174  3 180  Average 174

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● Water Absorption:The water absorption testing results

► Maximum water absorption value specified in ASTM C 55-06 equal 240 kg/m3.

Reusing wastewater (cont’d)

Mix Sample Number Water absorption (kg/m³)  1 225

A (Clean water) 2 230  3 229  Average 228  1 212

B (Paint Wastewater) 2 215  3 216  Average 214  1 206

C (Dye Wastewater) 2 208  3 209

Average 208

● Toxicity Characteristic Leaching Procedure (TCLP) Test:

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TCLP test results of the bricks

Reusing wastewater (cont’d)

Paint WW Dye WW Metals (mg/L) (mg/L) EPA limit (mg/L)

Arsenic (As) ˂ 5.0 ˂ 5.0 5.0Cadmium (Cd) ˂ 0.05 ˂ 0.05 1.0

Chromium Cr(total) 0.22 1.3 5.0Copper (Cu) 0.007 2.8 15.0

Mercury (Hg) ˂ 0.001 0.06 0.2Lead (Pb) ˂ 0.1 1.2 5.0Zinc (Zn) ˂ 0.03 4.2 25.0Iron (Fe) ˂ 0.05 3.5 5.0

Nickel (Ni) 0.079 2.5 7.0Chloroform (CHCl3) ˂ 5.0 2.1 6.0

Chlorobenzene ˂ 5.0 20 100

● Sulfide and Cyanides:

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● Ignitability and Corrosivity:

Reusing wastewater (cont’d)

Mix Sulfide, (mg/kg) Cyanides, (mg/kg)

B (Paint wastewater) 1.52 ˂ 1.0

C (Dye wastewater) 4.50 ˂ 1.0

EPA limit 500 250

Mix Ignitability, °C (°F) Corrosivity, pH

B (Paint wastewater) 100°C (212°F) 10.0

C (Dye wastewater) 110°C (230°F) 11.2

EPA limit Less than 60°C (140°F) (corrosive)pH < 2 or > 12.5

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Cement tiles

The mix proportions to produce 6 m2 tiles

Reusing wastewater (cont’d)

Tile: 30*30*2 cmRaw

Material/Mixture No. A

(Clean water) B

(Paint WW)C

(Dye WW) Coarse aggregate (kg) 120.0 120.0 120.0

Clean water (L) 15.0 N/A N/A Wastewater (L) N/A 15.0 15.0

Cement (kg) 50.0 50.0 50.0Fine aggregate (kg) 70.0 70.0 70.0

BVF (litter) 1.0 1.0 1.0

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● Compressive Strength: (Sample: 15*15*15 cm):Arduous service

Compressive strength of the tiles after 28 days

Reusing wastewater (cont’d)

Mix Sample Number Max. Stress (kg/cm²)  1 701

A (Clean water) 2 736  3 671  Average 702  1 688

B (Paint WW) 2 680  3 685  Average 684  1 700

C (Dye WW) 2 693  3 691

Average 695

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Bending strength of the tiles after 28 days

● Bending Strength: (Sample: 30*10*2.0 cm): Arduous service

Reusing wastewater (cont’d)

Mix Sample Number Max. Stress (kg/cm²)  1 88.7

A (Clean water) 2 89.2  3 93.85  Average 89.93  1 95.54

B (Paint WW) 2 95.7  3 93.48  Average 94.61  1 95.4

C (Dye WW) 2 96.5  3 93.2  Average 96.12

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The water absorption testing results of the tiles

● Water Absorption: must not exceed the 8% maximum percentage specified in E.S.S 269-2005.

Reusing wastewater (cont’d)

Mix Sample Number %  1 4.44

A (Clean water) 2 4.57  3 4.7

  Average 4.57  1 4.56

B (Paint WW) 2 4.55  3 4.22

  Average 4.44  1 4.41

C (Dye WW) 2 4.15  3 4.2

  Average 4.25

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● Toxicity Characteristic Leaching Procedure (TCLP) Test:

TCLP test results of the tiles

Reusing wastewater (cont’d)

Paint WW Dye WW

Metals Conc. (mg/l) Conc. (mg/l) EPA Limits (mg/l)

Nickel (Ni) ˂ 0.05 0.6 7.0

Cadmium (Cd) ˂ 0.05 ˂ 0.05 1.0

Copper (Cu) 0.005 0.1 15.0

Chromium Cr(total) 0.3 0.5 5.0

Lead (Pb) ˂ 0.1 ˂ 1.0 5.0

Zinc (Zn) ˂ 0.05 2.0 25.0

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● Abrasion resistance: (Sample 30*30*2 cm): Arduous service

The abrasion testing results of the tiles

Reusing wastewater (cont’d)

Mix Sample Number Loss in thickness, mm   1 0.91 A (Clean water) 2 0.71

  3 0.70  Average 0.75  1 0.93

B (Paint WW) 2 0.97  3 0.97  Average 0.97  1 0.82

C (Dye WW) 2 0.79  3 0.84  Average 0.81

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Recommendation● Construct a unit to produce the cement bricks and tiles near to

the wastewater stream.

Egg-laying machine

Concrete mixer

Tile machine

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Conclusion

● Reuse wastewater generated by the paint and textile manufacturing industries.

The monthly volumes of wastewater going for treatment (wastewater from washing and cleaning the tanks)

0

10000

20000

30000

40000

Month-year

Vol

um

e(G

allo

n)

(Source: with permission from CMB Company, Egypt)

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Conclusion (cont’d)

Different shapes of cement bricks Different shapes of cement tiles

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Questions?