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 Ltdleif.ramm-schmidt@rsconsulting.fig

Chandan Kumar, Arvind Envisol Pvt. Limited Limited chandan.kumar@arvind.in

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