env - wastewater recycling plants

7/28/2019 ENV - Wastewater Recycling Plants

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19/03/03 Transparent Technologies Pvt Ltd 1

Wastewater Recycling Plants withWastewater Recycling Plants withZero Effluent DischargeZero Effluent Discharge

By

Transparent Technologies Private Limited

Business Groups Websites

Co-generation systems www.tesplcogen.com

Absorption Cooling Systems www.tesplaarp.com

Water Recycling Plants www.waterrecyclingplant.comHeat recovery systems, Boilers & Heaters www.tespl.com

Dryers and Pollution Control www.ttplpune.com
http://www.tesplcogen.com/http://www.tesplaarp.com/http://www.waterrecyclingplant.com/http://www.tespl.com/http://www.ttplpune.com/http://www.ttplpune.com/http://www.tespl.com/http://www.waterrecyclingplant.com/http://www.tesplaarp.com/http://www.tesplcogen.com/


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Why Recycle Water?Why Recycle Water?

To cater to increased water demand due to

9 Urbanisation & Industrialisation.

9 Reduced rain falls.

9 Increase in standard of living.

9 Depletion in natural water resources.

Prevention of water pollution

9 Disposal of inadequately cleaned wastewater contaminates other fresh

water resources.

9 Industry will recycle water only if they are forced to generate their fresh

water resources from the wastewater generated by them.

9 It is economical to use recycled water than to pay for fresh water.

Social Obligation

9 Disposal of wastewater may damage your own health and surrounding.

9 Damaged nature around you will bring down your own quality of living.


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Typical Process Flow Sheet For CompleteWater Recycling With Zero Effluent

DischargeSuspended SolidsRemoval

SedimentationFiltration

Gases & Volatiles RemovalStripping

DegassingMembrane Process

Multi-stageEva oration

DryingPaddle dryerFlash Dryer

Fluidised Bed

Concentrate Water

Crystallization &

Concentrate

DryingS ra Dr er

Water saved throughrecycling

Condensate after-treatmentNeutralization / pHadjustmentAerationWet Oxidation

Oil SeparationFlotation


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How Transparent Water Recycling Plant PaysHow Transparent Water Recycling Plant Pays

for Itself?for Itself?

Water obtained is as good as distilled water.

Can be directly used in boiler and cooling towers. This saves-9 Fresh raw water costs.

9 Water treatment costs.

9 Boiler and cooling water blow down losses.

9 Reduced heat exchanger fouling increases productivity and energyefficiency.

9 Lowers cost of production

Reduces likely public liability costs.

Promotes public goodwill & Brand image and recognition in society.9 This increases share value.

9 Employee motivation and self esteem.

9 Business growth.


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How Transparent Water Recycling Plant PaysHow Transparent Water Recycling Plant Pays

for Itself?for Itself?

Improves productivity due to-

9 Better health of employees and their attendance.

9 Employee motivation and pride in their job.

The energy source for water recycling plant could be waste heat from.

9 Incinerator, furnace, or engine exhaust.

9 Engine jacket cooling water.


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Why WaterWhy Water--Recycling Plants are Tailor Made?Recycling Plants are Tailor Made?

Wastewater characteristics vary widely from industry to industry.

In every case pilot tests have to be carried out to establish-

9 Behaviour of wastewater.

9Suitability and type of evaporation technology.

9 Conditioning of wastewater required before and after evaporation.

The composition of wastewater make every plant to be tailor made.


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Pilot Plant Facilities AvailablePilot Plant Facilities Available

Transparent has built pilot plant facilities for evaporators and condensate

polishing equipments as given below-

9 Falling film.

9 Assisted rising film.

9 Forced circulation.

9 Ultra violet rays assisted wet oxidation for COD removal & condensate

polishing.

9 High-pressure, high temperature based wet oxidation for COD removal &

condensate polishing.

9 Activated carbon filter for condensate polishing.

9 Spray dryer for concentrate drying.


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Exclusive Features of Transparent WastewaterExclusive Features of Transparent Wastewater

Recycling PlantsRecycling Plants

High evaporation efficiency typically-

9 3 stage plant 4.4 kg water evaporation per kg motive steam.9 5 stage plant 7 kg water evaporation per kg motive steam.

9 7 stage plant 10 kg water evaporation per kg motive steam

Multi-staging and Thermo-compression increases efficiency of plant.

The driving source of heat can be-9 Incinerator, furnace, or engine exhaust.

9 Engine jacket cooling water.

Fully automatic. Needs no running attention.

Continuous modulation control of all parameters for each stage enables plantto accept reasonable variations in wastewater concentration.

Special purging system for degassing of wastewater.

Reliable instrumentation ensures uninterrupted operation.


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Types of Technologies Offered by TransparentTypes of Technologies Offered by Transparent

The main types of evaporation technologies employed are-

9 Falling film.

9 Assisted rising film.

9 Forced circulation.

The wastewater characteristics may demand one or more technologies to be

combined together to get desired solution viz.

9 Falling film evaporator stages followed by assisted rising film or forced

circulation.

9 Assisted rising film stages followed by forced circulation type.


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Falling Film Type EvaporatorFalling Film Type Evaporator

Downward parallel flow.

Uniform distribution of liquid.

Adequate re-circulation liquid

loading.

High heat transfer coefficient.

Lower temperature difference

operation.

Fully automatic level control

system. Both vacuum and pressurised

operation possible.

Ease in cleaning & repairs.


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Forced Rising Film Type EvaporatorForced Rising Film Type Evaporator

Upward parallel flow.

Moderate liquid re-circulation rate.

Lower temperature differenceoperation.


system.

Both vacuum and pressurisedoperation possible.

Ease in cleaning and repairs.


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Forced Circulation Type EvaporatorForced Circulation Type Evaporator

Liquid is heated under pressure

below its boiling point in heat

exchanger.

The sensible heat of liquid is

utilised to evaporate partial liquid

in flash vessel.

Liquid re-circulation rate is high.

It requires higher temperature

difference operation.


system.

Both vacuum and pressurised

operation possible.

Ease in cleaning and repairs.


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Industrial ApplicationsIndustrial Applications

9 Distilleries & Breweries

9 Pesticides & Insecticides

9 Dyestuff

9 Textile & Dyeing

9 Paper & Pulp

9 Pharmaceuticals & Bulk Drugs

9 Food processing

9 Meat processing

9 Fisheries & Fish processing9 Beverage Bottling Plants

9 Dairy

9 Chemical & Fine Chemicals

9 Paints & Pigments

9 Agrochemicals & Fertiliser

9 Solvent Extraction & Edible Oil

Refineries

9 Ink & Varnish

9 Hotels, Laundries & Hospitals

9 Sugar

9

Any other industry generatingwastewater


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CASE STUDYCASE STUDY

Wastewater Recycling cum Zero EffluentWastewater Recycling cum Zero EffluentDischarge Plant for Pharmaceutical IndustryDischarge Plant for Pharmaceutical Industry

The effluent characteristics are given below

9 Effluent capacity 50 TPD9 TDS 50,000 ppm

9 Ca & Mg hardness Less than 20 ppm

9 Volatiles & dissolved gases upto 1% w/w

9 TSS 4,000 ppm9 COD of effluent 60,000 ppm

9 Some of the Solvents present Pyridine, Ethylene,Methanol, Acetone

9 Water recycled 45 TPD

4 stage plant (first 3 stages of falling film followed by forced circulation stage)operating under vacuum with steam driven thermo-compressor.

Exclusive features of the system are mentioned below-


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Case StudyCase Study Purging system:

9 Provided to remove the dissolved gases.

9 Some volatiles and solvents may also get removed.

Falling film evaporators:

9 Adequate liquid loading per tube avoids hot spots and scaling.

9 Design of distributor system ensures proper film formation.

9 Proper sizes and location of vacuum piping on shell side ensure removalof gasses and volatiles.

Cyclonic Mist Eliminator:

9 Removes fine droplets entrained in the vapours.9 Condensate obtained is crystal clear as demonstrated on potassium

permanganate solution and on effluent.

Fully Automatic Plant:

9 Effluent tank level controller maintains effluent level in tank.9 Each stage has a flow control valve with PID controller and a level

transmitter.

9 Pumps have low safety trips avoids dry running.


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Case StudyCase Study

9 Concentration controller maintains concentration of concentrate even

when feed concentration varies.

9 Steam control valve avoids over heating of tubes by stopping steam

when any safety is actuated.

Steam Driven Thermo-compressor:

9 Compresses vapours from second stage and delivers to first stage shell

side.

9Improves thermal efficiency of plant.

Condensate polishing equipment:

9 The condensate obtained have volatiles with COD of 10,000 to 12,000

ppm

9 Methods to remove COD are-9 Thermal distillation: high initial & running cost.

9 Activated Carbon: solvents are absorbed in activated carbon. 1 R & 1 S

unit for uninterrupted working.


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9 Ultra violet rays assisted wet oxidation process: In the presence of catalyst& ultra violet rays the hydrogen peroxide reacts quickly with solvents &volatiles reducing its COD.

9 High pressure, high temperature based wet oxidation process: At high

temperature & pressure many solvents & volatiles gets degenerated andquickly reacts with hydrogen peroxide reducing COD.

Spray Dryer:

9 The concentrate and solvent mixture is spray dried.

9 The powder is separated in cyclone separator.

Incinerator:

9 The dried powder & gas has organic matter that needs to be incineratedbefore discharging to atmosphere.

9 Most organic materials get destroyed at 1000C. Sufficient residence time

provided for 99.9% destruction.

9 Fuel HSD is burnt in incinerator.

9 The ash is separated by cyclone separator, cooled and collected in BulkFlow Cooler.


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9 The scrubbing liquid will be changed periodically and spray dried in the

spray chamber itself.9 Some portion of hot gas is used in spray dryer improving thermal

efficiency of plant.

9 The gas is quenched and scrubbed in ventury wet scrubber.

9 Waste heat recovery boiler instead of quencher will improve the thermalefficiency of plant further.

9 Depending upon composition of effluent, scrubbing liquid may be water,

alkali, or any other reagent.

Thus Transparent has achieved water recycling with zero effluent discharge.

env - wastewater recycling plants

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