industrial wastewater reuse_anil sharma_2013
DESCRIPTION
The global water challenges, reuse of industrial wastewater and ZeeWeed MBR technology information.TRANSCRIPT
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Industrial Wastewater Reuse
December 13, 2013
Anil Sharma, P.Eng
Regional Leader – Process, APAC
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Presentation Outline
• General
• ZeeWeed MBR Technology
• Industrial Wastewater Reuse Case Studies
• Automotive
• Refinery/Petrochemical
• Food & Beverages
• Conclusions
• Q&A
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Global water challenges
Availability
Quality
Energy
Environmental
• Growing population and industry• Climate change and draught
• Deteriorating water quality• Increased industrial pollution
• Energy to increase ~30% by 2030• Demand for water to increase ~40%
• Stricter regulation on discharge/withdrawal• Water reuse incentives and mandates
Growing water scarcity and impairment
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Types of Reuse
Urban Reuse
• Irrigation of parks, highway medians, golf courses, etc.
• Commercial uses such as vehicle washing, window washing, etc.
• Fire protection
• Dust control and concrete production
• Toilet and urinal flushing
• Construction water
Groundwater recharge
• Aquifer reinjection
• Subsurface infiltration
• Surface infiltration
Industrial Reuse• Cooling water
• Boiler make-up water
• Industrial process water
Agricultural reuse
Environmental and recreational
• To create, restore, and/or enhance wetlands
• Recreational and aesthetic impoundments eg. Ornamental ponds
Reclaimed wastewater is an increasingly important source of supply
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• Municipal Water
• Marine & Defence
• Consumer (Retail)
• Municipal Sewage
• Water Reuse
• Land Development
• Marine & Defence
Make-up water for:
• Boiler feed
• Cooling towers
• Process water
• Membrane Bioreactor
• Tertiary filtration
• Water reuse
CoreMembraneTechnology
SewageIndustrialUF Pre-
treatment
IndustrialWaste-Water
DrinkingWater
GE Water’s UF/MBR Membrane Technology Applications
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ZeeWeed Technology
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MBR (Membrane Bio Reactor) & Tertiary Treatment
ZeeWeed® MBR Simplified Treatment Process
ZeeWeed® Tertiary Filtration Process
Wastewater
High Quality
Effluent for
RO Feed
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ZeeWeed® MBR
10,000 to 15,000 mg/l
Bioreactor Membrane(liquid/solids separation)
Hi-Rate Biological Treatment
• large capacity throughput
• compact footprint
• advanced treatment
• simpler, more reliable process
Absolute / Positive Filter• high degree of biomass/solids control• consistently high effluent quality• lower operator attention - less components
InfluentFiltrate(Effluent)
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ZeeWeed® MBR Technology
• Immersed
• Hollow fiber
• Outside-in
• Ultrafiltration (UF)
• PVDF (chlorine and oxidant-resistant) polymer
0.04 µm
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ZeeWeed = Consistent High Quality Effluent
Achievable ZeeWeedTreatment Results
BOD5 < 5 mg/L
TSS < 1 mg/L
NH3-N < 0.05 mg/L
TN < 3 mg/L*
TP < 0.05 mg/L*
Turbidity < 0.1 NTU
SDI < 3
* With appropriate biological design ** After disinfection
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Industrial Wastewater Reuse
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Specifics of Industrial Wastewater Reuse Treatment
General Considerations!
• Treatability of Wastewater or achievability of effluent requirements is always questionable!
• Wastewater characteristics can be completely different from one application to next within same industrial segment
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• Extreme pH variations
• Non (readily) biodegradable fractions (COD, organic N)
• Nutrient deficiencies (N, P, ions)
• Extremely high influent concentration (COD, N, P, etc.)
• High solids concentrations (TSS, VSS)/ inert material
• high temperatures
• high/ low TDS
• inhibitory compounds or toxic compounds
• other compounds to be considered for design, e.g. sulphides
• Foulants/ Scalants (colloidal material, free oil, scalants)
Piloting is an essential tool for accurate design
Specifics of Industrial Wastewater Reuse Treatment
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Automotive Industry Wastewater Reuse
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Automotive WW Treatment
GM Tonawanda, NY, USA
SMART Car, Hambach, France
Ford Hermosillo, Mexico
Ferrari Maranello, Italy
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The Coolest: Ferrari Maranello, Italy
• Plant expansion & addition of new paint facility required an upgrade of the existing water treatment facility
• Engineering consultants Fenice Spa & Desa Srl recommended MBR technology
• GE MBR at Fiat Mirafiori’s plant had successfully demonstrated the technology in a similar application
• 53,000 gpd
• MBR configuration: 2 trains x 8 cassettes x 20 ZW 500c modules
• Commissioned Jan 2004
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Toyota Kirloskar, Mysore Road
Membrane Bioreactor Treatment Process
Water Reuse in the processDesign Flow: 860m3/day
Influent Wastewater:
• BOD: 100 mg/L
• COD: 550 mg/L
• TSS: 650mg/L
Treated Effluent:
• BOD: <5mg/L
• COD: <30mg/:
• TSS: <5mg/L
Plant Commissioned 2011
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Volkswagen, Pune
Membrane Bioreactor Treatment Process
Water Reuse in the processDesign Flow: 860m3/day
Influent Wastewater:
• BOD: 625 mg/L
• COD: 1250mg/L
• TSS: 350mg/L
Treated Effluent:
• BOD: <5mg/L
• COD: <30mg/
• TSS: <5mg/L
Plant Commissioned: 2010
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Refinery & Petrochemical Reuse
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PEMEX Refinery, Mexico
Tertiary treatment of combined refinery effluent as pretreatment for RO
Located in Minatitlan, Mexico at one of Mexico’s largest refineries (173,200 bpd)
Wastewater treatment for reuse in the refinery – overall water recycle efficiency is 70%
RO permeate reused for cooling tower makeup and low-pressure boiler feed
Treatment capacity of 6.8 MGD
Commissioned in November 2001
Drivers – process reliability, cost savings
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PEMEX Refinery, Mexico
UF membrane process trains
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PEMEX Refinery, Mexico
Secondary effluent to UF
Treated effluent, RO feed
BOD (mg/L) 50 < 5
TSS (mg/L) 200 < 1
Turbidity (NTU) 25 < 0.1
SDI (-) N/A < 3.0
UF system performance data
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Membranes Immersed in Process Tank @ 85,000 mg/L FOG After Upset!
Cassette Fully Restored After Recovery Cleaning!
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SBRAPI/TPI/DAF Membrane Bio Reactor
Influent Reuse
India Refinery ProjectsEIL – Engineering Consultant
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MBR Case Study: Refinery Wastewater
BORL Bina
Customer Challenge
Treatment of refinery wastewater for reuse in process
Application Wastewater Reuse
Industry Refinery
Capacity 9.0 MLD
Location Bina, Madhya Pradesh, India
Year of Commissioning
2008
System ZW MBR
MembranesZW 500 D Hollow fiber Outside- in
Partner HDO
Parameter InfluentEffluent (Design)
BOD 50 <5
COD 300 <20*
TSS 100 <1
FOG 10 0
P 5 <1
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HPCL RefineryOwner Name HPCL
Location: Mumbai
System Type: ZeeWeed® MBR
Membrane Type: ZeeWeed® 500
Flow Rate: 7.2 MLD
Feed Source: Refinery Wastewater
GE’s Discharge Requirement:
BOD < 5 mg/L
COD < 20* mg/L
TN* < 7 mg/L
Turbidity < 1NTU
And other parameters
Process: Nitrification/De-nitrification
Commissioned: 2010
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HMEL RefineryOwner Name HMEL Refinery
Location: Punjab
System Type: ZeeWeed® MBR
Membrane Type: ZeeWeed® 500
Flow Rate: 12 MLD
Feed Source: Refinery Wastewater
GE’s Discharge Requirement:
BOD < 5 mg/L
COD < 20* mg/L
TN* < 7 mg/L
Turbidity < 1NTU
And other parameters
Process: Nitrification/De-nitrification
Commissioned: 2012
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India Petrochemical Wastewater ReuseReliance Dahej PTA Effluent Treatment
• Membrane Bio Reactor Technology for Treatment and Reuse
• Approximately 45 MLD in 4 different Modules will make it Largest MBR in Petrochemical Industry
• Under Installation
Influent Wastewater:
• BOD: 500 – 600 mg/L
• COD: 1,300 – 1,500 mg/L
• TSS: 50 – 140mg/L
Expected Effluent Quality:
• BOD: <5mg/L
• COD: <30 - 40mg/L
• TSS: ND
Turbidity: ≤ 0.5 NTU (100% of the time)
≤ 0.1 NTU (90% of the time)
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Food & Beverages Wastewater Reuse
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Nestle Anderson, Indiana Nesquick/Coffeemate wastewater• $360M factory and distribution center for Nestle’sBeverage division
• 880,000 square foot facility produces ready-to-drink milk products like Nesquick and Coffee-Mate products
• Limited existing sewer flows
• Downstream POTW capacity was insufficient to treat increased organic & solids load
• Solution: 1.14 MGD MBR
• Commissioned in Summer 2008
• Up to 80% of the MBR permeate is reused for non-product contact applications eg. cooling tower makeup
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Coca Cola, Puerto RicoSoft Drink Bottling Plant • New WWTP to treat increased bottling plant flow
• High cost of WW disposal – trucked to POTW
• Overdrawing existing well water supply
• Solution: MBR (January 2004) + RO
• Average flow / peak flow: 72,000 / 121,000 gpd
• High influent flow variations and wastewater strength:
– COD – up to 19,000 mg/L
– BOD – up to 9,200 mg/L
– TSS ~ 50 mg/L
– TP ~30 mg/L
• Achievement of total reuse of treated wastewater
– 100,000 gpd water savings to plant
– Economically feasible: savings far exceed costs
Bioreactor
Membrane skids
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Nestle India Plants
• Nestle Manesar
• Nestle Himachal
• Nestle Moga
• Nestle SriLanka
• Nestle Panipat
Design Flow Ranges from 250m3/day to 1,800 m3/day
Influent BOD Range: 400 – 1,800mg/L
Influent COD Range: 1200 to 4,000mg/L
Treated Water being reused for process and cooling towers etc.
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Conclusions
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ConclusionsDemands
Exist for wastewater reuse in each type of industry
Immersed hollow fiber membranes fit the needTo treat industrial wastewater to the levels required for
reuse
Immersed hollow fiber membranes are the state-of-the-art
In the treatment of “Tough To Treat” Wastewater for reuse
Full-scale membrane facilities treating various Industrial wastewater exist
Proving the technical feasibility of MBR Technology
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Questions?