rtw - macrosorb profile (feb 2010)

Macrosorb®MacrosorbEffluent Treatment SystemsEffluent Treatment Systems

RTW DevelopmentRTW Development

What is Macrosorb® ?What is Macrosorb® ?

• Macrosorb® is a water treatment agent• Macrosorb® is a water treatment agent

• Synthetic inorganic clay

• Manufactured by RTW Development Ltd. under license from Ineos Silicas Ltd.

• Anion exchanger with inter layer carbonate ions

• Designed specifically for colour removal

• Also significantly reduces COD and BOD

• Basis of the Macrosorb® Effluent Treatment System


Basis of the Macrosorb Effluent Treatment System

How does Macrosorb® work?How does Macrosorb® work?

• Anion exchangerg

• Dye anions are attracted to the Macrosorb® surface

• Precipitation stage removes organics• Precipitation stage removes organics

• A floc is formed which settles rapidly

• After separation the treated water can be reused


Key FeaturesKey Features

• Developed to remove virtually all dyes and pigments fromdyehouse effluentdyehouse effluent

• Absorption takes place rapidly reducing contaminants tovery low levelsvery low levels

• Additional benefit of much reduced BOD and COD

Th t t d t b d th ll i f• The treated water can be re-used thus allowing for apayback on the equipment

Uses rob st simple to operate and maintain eq ipment• Uses robust, simple to operate and maintain equipment,having a small foot print and requiring minimal civilengineering on site


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Macrosorb® Treatment PlantMacrosorb® Treatment Plant

Balancing Tank Fixed

Dyehouse

Biological

Macrosorb

pH Controller

GrowthReactor

Reaction Tank 1

BiologicalClarifier

(Sulphuric Acid)Tank 1

Reaction Tank 2

pH Tank ChlorineC t t

pH Controller(C ti S d )

pH Controller(Caustic Soda)

Coagulant

Tank 2

Reaction Solids Separator

ContactTank

(Caustic Soda)( )

Treated Effluent DischargeTank 3 Solids Separator

RTW DevelopmentRTW DevelopmentFilter Cake Filter Press

Dyes removedDyes removed

• Acid dyes - generally easily removed

• Metal Complex dyes - 2:1 and 1:1 dyes are readily absorbed

• Reactive dyes - The Macrosorb® System was designed toremove all types of reactive dyes, the cause of the biggestcolour problem in dyehouse effluent

• Disperse dyes - Macrosorb® works well with a range ofdisperse dyes

• Direct dyes - easily removed

• Azoic, vat and sulphur dyes - not truly in solution, they ared i th i it ti t

RTW DevelopmentRTW Developmentremoved in the precipitation stage

Colour RemovalColour Removal

Treated Consent Untreatedabsorbance

1.5

1.8 Treated Consent Untreated

0.9

1.2

0.3

0.6

0400 450 500 550 600 650 700

Wavelength (nm)

RTW DevelopmentRTW DevelopmentEffluent from reactive dyeing of cotton

COD RemovalCOD Removal

Effluent Untreated After Macrosorb Removal %

Cotton 1100 275 75

Cotton/poly 1000 300 70

Cotton/nylon 950 300 68Cotton/nylon 950 300 68

Cotton/wool 1400 500 65

Nylon 600 200 66


Water Re-useWater Re-use

• The treated water is colour free and has a much reduced COD

• The residual COD is made of non-ionic surfactants and formic / acetic acid

• 2-4gpl sodium chloride typically remains in solution (reactive dyeing)

• 60% water re-use is possible with minimal changes in the dyehousey


Payback PotentialPayback Potential

• If the treated water is re-used in the dyehouse:

– The heat in the water is re-used and saved

– Reduction in incoming water cost

– Reduction in effluent charge

• In certain cases the above can provide sufficient savings to• In certain cases the above can provide sufficient savings to payback the initial investment in 2-3 years

• Our custom designed spread sheet can calculate costs andOur custom designed spread sheet can calculate costs and savings and predict the payback period


Key FeaturesKey Features

• Developed to remove virtually all dyes and pigments from dyehouse effluentdyehouse effluent

• Absorption takes place rapidly reducing contaminants to very low levelsvery low levels

• Additional benefit of much reduced BOD and COD

Th t t d t b d th ll i f• The treated water can be re-used thus allowing for a payback on the equipment

Uses rob st simple to operate and maintain• Uses robust, simple to operate and maintain equipment, having a small foot print and requiring minimal civil engineering on site


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The EquipmentThe Equipment

• The plant required consists of simple fibreglass reactiontanks stirrers and dosing pumpstanks, stirrers and dosing pumps

• As the process is carried out in a number of tanks, if lackof space is a problem the plant can be split upof space is a problem the plant can be split up

• The system is designed to require only basicmaintenance - easily carried out by in house engineersmaintenance - easily carried out by in house engineers

• The plant can be installed with minimal disruption to thedyehousedyehouse

• As supplied the plant can be highly automated and PLCcontrolled, requiring little operator input


controlled, requiring little operator input

Our ExperienceOur Experience

• Dyehouses using Macrosorb® with a wide range of dyed fibresDyehouses using Macrosorb with a wide range of dyed fibres

– Cotton, cotton blends, polyester, nylon, wool & rayon

• Macrosorb ® Effluent treatment plants operating in many countries

UK (1995) Netherlands (1996) China (1996) Philippines– UK (1995), Netherlands (1996), China (1996), Philippines (1997), Thailand (2002), Cambodia (2003), Pakistan (2004), France (2004) Vietnam (2005) Sri Lanka (2006) BangladeshFrance (2004), Vietnam (2005), Sri Lanka (2006), Bangladesh, Dhaka (2007) & Bangladesh, Chittagong (2009)


Coats Manila BayCoats Manila Bay

• Originally used aluminium sulphate

• Converted to Macrosorb in March 1999

• Used the existing equipmentg q p

• RTW Development added

control and dosing module (containerised)– control and dosing module (containerised)

– solids separator

– plate and frame filter press


Macrosorb Effluent Treatment PlantCoats Manila Bay

Existing Balancing Tank - 600m3 in-ground concrete

Tanks 1 and 2 - In-ground concrete Solids Separator - High rate crossflow clarifier

Dosing and control container - Fully automatic, computer controlled, pre-commissioned

Plate and frame filter press

Filter cake - Non hazardous, 30% dry solids Treated water before discharge to river

Chung LapChung Lap

• Hong Kong JV dyehouse in Dongguang g y gg

• Originally used aluminium sulphate

• Converted to Macrosorb in December 1999• Converted to Macrosorb in December 1999

• Used the existing equipment

• 3200m3 per day effluent

• RTW Development added

– control and dosing module (Cube)


Dosing and control cube, semi-automatic, pre-commissioned

Chung Lap ResultsChung Lap Results

COD( /L)

BOD( /L)

SS( /L)

Colour(ABS 550 )

pH(mg/L) (mg/L) (mg/L) (ABS 550nm)

Untreated 464 24.6 191 0.759(dilution 90 100)

9.89(dilution ~ 90-100)

AfterMacrosorb

40 3.3 1 0.041(dilution < 10)

7.81

Allowed limit 100 40 70 dilution 40 6-9

Typical data 230 50 120 dilution 70 8Typical dataprior to useof Macrosorb

230 50 120 dilution 70 8

RTW DevelopmentRTW DevelopmentTested at HK Polytechnic University

Filter CakeFilter Cake

Wool dyeing & scouring effluent (%)

Cotton dyeing & scouring effluent (%) g ( ) g ( )

Water 77 77

Inorganics 11 12Inorganics 11 12

Organics 12 11

Chromium 0.001 0.001

Copper 0.001 0.001Copper 0.001 0.001

Mothproofer 0.001 Nil


Filter cake is non hazardous and disposed to landfill

Macrosorb® vs Metal SaltsMacrosorb® vs. Metal Salts

• Better colour removal - can remove so much dye that the solution appears colourless, other systems leave residual dye

• Better COD and BOD removal - subsequent treatment may not be needed

• Produces less sludge - because Macrosorb is more effective, less can be used to achieve the required colour consentused to achieve the required colour consent

• Rapid Settlement - the floc formed is very dense, allowing for separation in a much lower surface area and hence smaller plant

• Less dye selective - conventional systems are very dye-specific

• Less pH sensitive - Al and Fe systems require that pH of treatment is t l dj t d M b i h l itiaccurately adjusted, Macrosorb is much less sensitive.

• Water re-use - with the correct Macrosorb system water can be recycled to the dyehouse, other systems can only give recycled water when several


y y y g ysystems are used together in series.

About Ineos SilicasAbout Ineos Silicas

• Part of the Ineos group - UK second biggest chemical company

• Formerly Crosfield Limited

• Major supplier of inorganics based on silica and aluminaj pp g

• Manufacturing sites on 5 continents

• Has produced textile auxiliaries for over 25 years• Has produced textile auxiliaries for over 25 years

• Proven ability to advise on dyehouse practice

• RTW Development Limited has the exclusive license to manufacture and distribute Macrosorb ® world wide.


Further InformationFurther Information

RTW Development Limited704, Blissful Building

www.rtw.bizwww macrosorb net243-247 Des Voeux Road

Central,Hong Kong

www.macrosorb.net

Hong Kong

Contact: Rod WhalleyT l (852) 27812246Tel: (852) 27812246Fax: (852) 27812247 Email: [email protected]


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Important InformationImportant Information

All information contained in this publication is believed to be accurate and isi i d f i h RTW D l L d ld b l dgiven in good faith. RTW Development Ltd. would be very pleased to cooperate

with organizations who wish to explore further any resulting possibilities.However, readers must satisfy themselves as to the suitability of suchinformation for their own particular purpose This applies equally toinformation for their own particular purpose. This applies equally torecommendations or suggestions made by RTW Development Ltd. relating tothe use of information from this publication or offered in response to specificinquiries or otherwise. No warranty is given as to the fitness of the informationinquiries or otherwise. No warranty is given as to the fitness of the informationfor any particular purpose and any implied warranty or condition (statutory orotherwise) is excluded except insofar as such exclusion is prevented by law.RTW Development Ltd. accepts no liability for loss or damage (includingliability for negligence or other tortious act or omission) other than that causingdeath or personal injury arising from reliance on the information provided.Freedom from patent, copyright or design protection must not be assumed.


rtw - macrosorb profile (feb 2010)

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