Wastewater Recycling Plants with Zero Effluent Discharge

By

Transparent Technologies Private Limited

Business Groups
Co-generation systems Absorption Cooling Systems Water Recycling Plants Heat recovery systems, Boilers & Heaters Dryers and Pollution Control

Websites
www.tesplcogen.com www.tesplaarp.com www.waterrecyclingplant.com www.tespl.com www.ttplpune.com

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Transparent Technologies Pvt Ltd

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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Transparent Technologies Pvt Ltd

Typical Process Flow Sheet For Complete Water Recycling With Zero Effluent Discharge
Suspended Solids Removal Sedimentation Filtration Decanting Multi-stage Evaporation Oil Separation Flotation Oil Separator Gases & Volatiles Removal Stripping Degassing Membrane Process

Condensate Water

Concentrate Water

Condensate aftertreatment Neutralization / pH adjustment Aeration Wet Oxidation

Crystallization & Filtration

Drying Paddle dryer Flash Dryer Fluidised Bed

Concentrate

Water saved recycling

through Drying Spray Dryer Incineration Fluidized Bed Grate type For VOC + Solids

To Plant for reuse

Incineration Spray chamber type

Exhaust to Atmosphere

Gas Cleaning Bag Filter Wet Scrubber

Heat Recovery Unit Hot Water Thermic Fluid Steam

How Transparent Water Recycling Plant Pays for Itself?

Water obtained is as good as distilled water. Can be directly used in boiler and cooling towers. This saves9 Fresh raw water costs. 9 Water treatment costs. 9 Boiler and cooling water blow down losses. 9 Reduced heat exchanger fouling increases productivity and energy efficiency. 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 Pays for Itself?

Improves productivity due to9 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 Water-Recycling Plants are Tailor Made?

Wastewater characteristics vary widely from industry to industry. In every case pilot tests have to be carried out to establish9 Behaviour of wastewater. 9 Suitability 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 Available

Transparent has built pilot plant facilities for evaporators and condensate polishing equipments as given below9 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 Wastewater Recycling Plants

High evaporation efficiency typically9 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 be9 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 plant to 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 Transparent

The main types of evaporation technologies employed are9 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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Transparent Technologies Pvt Ltd

Falling 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 Evaporator

Upward parallel flow. Moderate liquid re-circulation rate. Lower temperature difference operation. Fully automatic level control system. Both vacuum and pressurised operation possible. Ease in cleaning and repairs.

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Forced 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. Fully automatic level control system. Both vacuum and pressurised operation possible. Ease in cleaning and repairs.
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Industrial Applications
9 9 9 9 9 9 9 9 9 9 9

Distilleries & Breweries Pesticides & Insecticides Dyestuff Textile & Dyeing Paper & Pulp Pharmaceuticals & Bulk Drugs Food processing Meat processing Fisheries & Fish processing Beverage Bottling Plants Dairy

9 9 9 9 9 9 9 9

Chemical & Fine Chemicals Paints & Pigments Agrochemicals & Fertiliser Solvent Extraction & Edible Oil Refineries Ink & Varnish Hotels, Laundries & Hospitals Sugar Any other industry generating wastewater

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CASE STUDY Wastewater Recycling cum Zero Effluent Discharge Plant for Pharmaceutical Industry

The effluent characteristics are given below 50 TPD 9 Effluent capacity 50,000 ppm 9 TDS Less than 20 ppm 9 Ca & Mg hardness upto 1% w/w 9 Volatiles & dissolved gases 4,000 ppm 9 TSS 60,000 ppm 9 COD of effluent 9 Some of the Solvents present Pyridine, Ethylene, Methanol, Acetone 45 TPD 9 Water recycled 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 belowTransparent Technologies Pvt Ltd 13

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Case 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 removal of 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 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. 9 Improves 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 are9 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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Case Study
& 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 and quickly 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 incinerated before 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 Bulk Flow Cooler.
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9 Ultra violet rays assisted wet oxidation process: In the presence of catalyst

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Case Study
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 thermal efficiency 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.

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