13th Asia Pacific Roundtable On Sustainable Consumption & Production (APRSCP)

SCP as a strategy for national energy,

water and food security

TOPIC 3 : Cleaner Production & Cost Reduction in Waste Management

By Lim Swee Choon Envilab Sdn Bhd

Cleaner Production & Cost Reduction In Waste Management

• High Strength Industrial Waste

• Treatment of High Strength Industrial Waste

• Vacuum Evaporation Technology

• Cleaner Production with Vacuum Evaporator

• Cost reduction in waste management

• Summary

Content :

•Air Pollution

•Water Pollution

•Environmental Pollution

All Industries Are Polluting !!!

How to make it sustainable ?

•End Of Pipe process

•No proper waste management system

• Increase Energy Consumption

• Increase Material Consumption

•Reduce Environmental Quality

•Tendency of illegal damping/discharge

Current Situation

Getting worst due to high demand

Definition :

• Organic (COD) > 10,000 mg/l

• Heavy Metals > 10,000 mg/l

• Oil & Grease > 10,000 mg/l

• Suspended Solids > 20,000 mg/l

High Strength Industrial Waste

Most challenging in Treatment of Industrial Waste to your business

Example :

• Ink Waste

• Photographic Developer

• Machine Waste Coolant

• Concentrated waste Chemicals

• Factory reject/expired products

• Reject from RO

• Electroplating bath

• Detergent/Cleaning bath (surface degreasing)

High Strength Industrial Waste

• Dispose at original volume & concentration

• High disposal cost (large volume)

• Convert small problems into somebody big problems

• NO treatment hassle

• Zero Capital cost

High Strength Industrial Waste

Treatment Option A Direct Disposal to Waste

Management Centre.

• Chemical & Biological treatment

• Complicated process

• Performance affected by strength of waste

• High chemicals cost

• High sludge disposal cost

• Difficult to achieve effluent discharge compliance

• Large foot print

High Strength Industrial Waste

Treatment Option B Conventional Processes

• Volume reduction

• Low disposal cost (low volume)

• Reuse of water or concentrate

• Simple process (physical)

• Performance regardless of waste strength

• Low foot print (compact system)

• High Capital cost

High Strength Industrial Waste

Treatment Option C Vacuum Evaporation

The Technology of Vacuum Evaporator

•Principle of boiling in a vacuum condition

•Less energy is needed (150 – 180 watt/liter)

•Evaporation at 35 – 45 °C

•Heat Pump (refrigerant compressor)

Process Description

Air Conditioner System

Vacuum Evaporator - Process Flow

Multi Effect - Process Flow

3° STAGE 1° STAGE 2° STAGE

ARIA

COOLING TOWER

HOT

WATER

V-NT Series

• Vertical vacuum evaporator

• Concentrates up to 20 times

• Fully automatic

• Heat pump technology

• Refrigeration cycle with

ecological refrigerant gas

• Use of special stainless steel

alloys for aggressive effluents

Vacuum Evaporator - Concentrator

Production Capacity

100 – 25,000 litres/day

ME Series

• 2 or 3 vertical vacuum

evaporators in series

• Concentrates up to 20 times

• Fully automatic

• Use of special stainless steel

alloys for aggressive effluents

• Treatment of larger volumes of

effluent

Production Capacity

10,000 – 50,000 litres/day

Vacuum Evaporator - Concentrator

ME Series

• Possible to use any alternative

energy source: (hot water,

steam, oil and by-products)

• Energy saving : energy only

needed to feed 1st evaporator,

• Use of cooling system to

condense steam produced by

last evaporator

Production Capacity

10,000 – 45,000 litres/day

ME Vacuum Evaporator

ES Series

• Horizontal vacuum evaporator

• Concentrates to dry mud/crystals

• Fully automatic with manual discharge

• Heat pump technology

• Refrigeration cycle with ecological

refrigerant gas

• Use of special stainless steel alloys for

aggressive effluents

Production Capacity

100 – 1,000 litres/day

Vacuum Evaporator - Dryer

Vacuum Evaporator - Dryer Model

Treatment Of Organics Waste

Treatment Of In-Organics Waste

Typical Process Reuse/Post

Treatment or Discharge Distillate Vacuum

Concentrator (1500 – 50,000 l/day)

High Strength Wastewater

Vacuum Dryer (250 – 1000 l/day)

Sludge/Cake (Disposal)

Concentrate (Reuse/disposal)

C&G Vacuum Evaporator

• Custom designed to meet specific requirements.

• Fully automatic working cycle.

• Extremely compact construction.

• Can operate using electric energy or heat source.

• Low energy consumption (yield 150 -180 W/l)

• No fumes or smell – enclosed system

• 24 hour performance.

• Simplicity and ease of operation and maintenance.

• Galvanic industries

• Foundries: die-casting, wire-drawing

• De-greasing washes with alkaline and detergents

• Graphic arts –developer waste

• Food industry

• Pharmaceutical

• Chemical (organics waste)

• Radioactive wastewater

• Paints waste

Main Areas of Application

All type of high strength industrial waste

•Business points

•Cost Benefits

•Environmental

•Resource Recovery ???

Incentives to use new technologies

Application of

Vacuum Evaporator in Cleaner Production

Objectives :

•To create a close-loop in the Nickel line.

•To install a process of “zero” discharge of nickel into the environment.

•To install a process to recover the precious raw materials and water

Ref: Vitri Electro-Metalurgica, Spain

Recovery of Chromium or Nickel

Recovery system and “0” discharge of nickel

Nickel bath

Rinsing Tanks

Chemical treatment

Discharge

Old Process Raw material

Rinsing water

Sludge

Nickel bath

Rinsing Tanks

Vacuum Evaporator

New Process Raw material

Distillate

Concentrate

Raw materials Old Process New Process

Nickel chloride 12.1 kg/year 1.6 kg/year

Nickel sulphate 7.02 kg/year 480 kg/year

Boric acid 3.9 kg/year 220 kg/year

Nickel anodes 10.88 kg/year 6.4 kg/year

Sludge from treatment plant 40.68 mt/year 12.64 mt/year

Cost of Raw Material 236.6 Thousand €/year 95.90 Thousand €/year

Treatment cost of wastewater 13.6 Thousand €/year 6.3 Thousand €/year

Total cost 250.2 Thousand €/year 102.2 Thousand €/year

Total Saving 148.0 Thousand €/year (12.3k/month)

Capital Investment 132.2 Thousand €

Investment return 11 months

Application of

Vacuum Evaporator Treatment of Coolants Waste

Cycle of Used Coolant without Vacuum Evaporator

Vacuum Evaporator – Coolant Waste

Investment Return

ROI ≈ 14 month

Vacuum evaporator

V-NT 3500

Concentration factor 10

Capacity of evaporator

(water treated Litres/hour

146.44

Cost of electric energy

(€/kWh)

0.078

Energy used for each litre

of distillate produced

(kW/l)

0.15

Cost of disposal of

concentrate (€/l)

0.146

Cost of disposal of

wasteweater as such

without the use of an

evaporator (€/l)

0.073

INITIAL INVESTIMENT (€) 92,000

0

10000

20000

30000

40000

50000

60000

70000

80000

90000

100000

110000

120000

130000

140000

150000

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

MONTHS

EURO

Disposal of untreated wastewater

Using C&G Evaporator

Application of

Vacuum Evaporator in Treatment of Paints Waste

Application of Vacuum Evaporator (Paints Waste Treatment)

ROI - Paint Waste Treatment Description Running Cost / month RM

Consumable

Electricity

Antifoam/Carbon

Spare parts cost

(average)

201.6 kWh @ RM 0.355/kWh @ 30 days

About 5kg/100 kg (monthly)

Level sensor, Pump Seal

2,147.00

1125.00

350.00

Scheduled

Waste

Concentrate from

Vacuum Evaporator

Waste is concentrate at around 10

times,

@ 1,680 L/month

Disposal Cost @ RM 2.00 / L

3,360.00

Total operation cost per month 6,982.00

Disposal cost for 14,400 L/month @ RM 2.00 / L (Without Evaporator) 28,800.00

Total saving per month 21,818.00

Investment cost 300,000.00

ROI 14 months

Paint Waste Treatment Plant

Application of

Vacuum Evaporator in Treatment of Organics Waste

Organics Waste Treatment

Production Plant Up-Set

Production Plant Normal

ROI - Organics Waste Treatment Description Running Cost / month RM

Consumable

Electricity

Antifoam/NaOH

Spare parts cost

(and other cost)

1269.6kWh/day @ RM 0.38/kWh @ 30

days

About 10kg/2000kg monthly

Level sensor, Pump Seal, Gasket,

operator

14,473.00

6,250.00

7,500.00

Scheduled

Waste

Concentrate from

Vacuum Evaporator

Waste is concentrate at least 8x times,

@ 18,750L/month

Disposal Cost @ RM 1.00 / Liter

18,750.00

Total operation cost per month 46,973.00

Disposal cost for 150,000L/month @ RM 1.00/Liter (without evaporator) 150,000.00

Total saving per month 103,027.00

Investment cost 950,000.00

ROI 9 months

In Summary

Vacuum Evaporation Technology

Reduce Waste Disposal cost/Environment Impact

Recycle of water or salt from wastewater (3R)

Achieving Cleaner Production & Reduce Pollution