Industrial Wastewater Reuse

December 13, 2013

Anil Sharma, P.Eng

Regional Leader – Process, APAC

Presentation Outline

• General

• ZeeWeed MBR Technology

• Industrial Wastewater Reuse Case Studies

• Automotive

• Refinery/Petrochemical

• Food & Beverages

• Conclusions

• Q&A

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

4

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

• 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

ZeeWeed Technology

MBR (Membrane Bio Reactor) & Tertiary Treatment

ZeeWeed® MBR Simplified Treatment Process

ZeeWeed® Tertiary Filtration Process

Wastewater

High Quality

Effluent for

RO Feed

8

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)

9

ZeeWeed® MBR Technology

• Immersed

• Hollow fiber

• Outside-in

• Ultrafiltration (UF)

• PVDF (chlorine and oxidant-resistant) polymer

0.04 µm

10

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

Industrial Wastewater Reuse

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

• 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

Automotive Industry Wastewater Reuse

Automotive WW Treatment

GM Tonawanda, NY, USA

SMART Car, Hambach, France

Ford Hermosillo, Mexico

Ferrari Maranello, Italy

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

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

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

Refinery & Petrochemical Reuse

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

PEMEX Refinery, Mexico

UF membrane process trains

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

Membranes Immersed in Process Tank @ 85,000 mg/L FOG After Upset!

Cassette Fully Restored After Recovery Cleaning!

SBRAPI/TPI/DAF Membrane Bio Reactor

Influent Reuse

India Refinery ProjectsEIL – Engineering Consultant

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

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

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

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)

Food & Beverages Wastewater Reuse

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

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

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.

Conclusions

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

Questions?