Journal of Environmental Science and Health, Part A

ISSN: 1093-4529 (Print) 1532-4117 (Online) Journal homepage: http://www.tandfonline.com/loi/lesa20

Effluent Management for a Metal Finishing

Industry Aiming Zero Discharge Conditions
FATOS GERMIRLI BABUNA , ISIK KABDASLI , SEVAL SZEN & DERIN ORHON
To cite this article: FATOS GERMIRLI BABUNA , ISIK KABDASLI , SEVAL SZEN & DERIN
ORHON (2006) Effluent Management for a Metal Finishing Industry Aiming Zero Discharge
Conditions, Journal of Environmental Science and Health, Part A, 41:9, 1793-1806, DOI:
10.1080/10934520600778978
To link to this article: http://dx.doi.org/10.1080/10934520600778978

Published online: 06 Feb 2007.

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Date: 27 October 2016, At: 01:05

Journal of Environmental Science and Health Part A, 41:17931806, 2006

C Taylor & Francis Group, LLC
Copyright

ISSN: 1093-4529 (Print); 1532-4117 (Online)
DOI: 10.1080/10934520600778978

Effluent Management for a

Metal Finishing Industry Aiming
Zero Discharge Conditions
Fatos Germirli Babuna, Isik Kabdasl, Seval Sozen,
and

Derin Orhon
Istanbul Technical University, Faculty of Civil Engineering, Environmental
Engineering Department, Maslak, Istanbul, Turkey
Technical applicability of zero discharge conditions is evaluated for the specific case of
a large metal finishing industry located within the protection zone of a surface water
body designated as a potential source for domestic water supply. Within the context of a
sound water management strategy, a detailed process profile of the plant is established
with relevant balance between water demand and wastewater generation. Quality
restrictions for various water uses are identified. Wastewater flows are segregated
depending on significant quality parameters. A comprehensive treatment scheme is
defined for optimum wastewater recycle and reuse. Source allocation is made for the
reuse of different streams of recycled wastewater. The study indicates that wastewater
reuse can only be implemented with an efficiency of around 8590% for the selected
industry.
Key Words: Effluent management; Industrial pollution; Metal finishing industry;
Reuse; Wastewater recycle; Zero discharge.

INTRODUCTION
Zero discharge or total wastewater recycle is a very fashionable concept mostly
advocated for industrial activities. It is an optimistic argument often set forth
in non technical discussions and/or environmental impact assessment studies,
without serious consideration on prohibitive cost involved, technical problems
to be faced, and in general, on its relevance to sustainable development. This
concept presents a major threat for developing countries, as it is likely to
affect the delicate balance between development, environmental concern and
investment allocations. Currently, although set as a goal to protect the natural

Address correspondence to Fatos Germirli Babuna, Istanbul Technical University,

Environmental Engineering Dept., Maslak 34469, Istanbul, Turkey; E-mail: fgbabuna@
ins.itu.edu.tr

1793

1794

Babuna et al.

resources in the developed parts of the world, relevant technological constrains

usually limits the application of zero discharge concept.[1]
Zero discharge is originally promoted for the protection of surface and/or
groundwater resources and irrigation is the most common procedure of
wastewater reclamation, mainly for domestic sewage.[2] The zero discharge potential is also explored and conceptually introduced for a number of industries
with high polluting characteristics.[35] Metal finishing is such an industrial
category in terms of the diversity of the processes involved all generating
wastes with toxic compounds.[6]
The study evaluates technical implications of zero discharge condition for
a large metal finishing plant as a representative case study. The plant is
located within the protection zone of a surface water body designated as a
potential source for consumption water supply. The study covers and provides
the necessary information on the technical steps required for a comprehensive
survey, involving detailed process profile, water demand, wastewater generation, wastewater segregation for optimum treatment, water balance and
conceptual basis of wastewater recycling. The selected effluent management
strategy and the wastewater reuse scheme are defined. The non-recoverable
portions of the wastewater, inherently generated as part of the treatment
scheme are identified. The results are interpreted in terms of the technical
feasibility of a zero discharge/total recycle situation for the plant.

DESCRIPTION OF THE INDUSTRY AND PRODUCTION PROCESSES

The industry under investigation is established on an area of 1,005,000 m2 ,
functions 5 days a week employing 3,211 personnel. As the plant is located
within the protection zone of a complex surface water resource system designed
for multi-purpose beneficial uses, mainly involving abstraction for human
consumption, it is permitted for no wastewater discharge. In other words due
to the type of the permit total recovery and reuse of wastewater generated in
the plant is required.
Four main production lines, namely; steel wheel production, tractor production, engine assembly shop and spring production are involved in the plant.
Steel wheel production is further divided into automobile steel wheel and
truck steel wheel workshops; while tractor parts painting, tractor assemble,
tractor parts machining, pres and sheet metal fabrication shops are included
in tractor production; leaf springs shop, coil springs shop and stabilizer bar
shop are sub-production lines of spring production. Production capacity of the
installation is tabulated in Table 1.
Heavy-duty tubeless, rear, passenger car, light commercial vehicle and
front tractor wheels are manufactured in truck and automobile steel wheel
workshops where discs produced by press and flow forming methods and rims

Effluent Management for a Metal Finishing Industry

1795

Table 1: Production capacity of the investigated plant.

Production
Steel wheel production
Truck steel wheel workshop
Automobile steel wheel workshop
Tractor production
Press shop
Sheet metal fabrication shop
Tractor parts machining shop
Tractor parts painting shop
Assembly shop
Spring production
Coil springs shop
Leaf springs shop
Stabilizer bar shop
Engine production
Engine assembly shop
Different

Unit

Capacity

(unit d1 )
(unit d1 )

1,230
9,000

(unit d1 )
(unit d1 )
(unit d1 )
(unit d1 )
(unit d1 )

110
110
110
110
110

(unit d1 )
(unit d1 )
(unit d1 )

4,750
90105
800

(unit d1 )

38,000

parts for 110 tractors.

manufactured by roll forming are assembled. Main operations of steel wheel

line are cutting, welding, milling, gauging, pre-degreasing, degreasing, rinsing,
disk manufacturing, assembling, parts machining, fracture control, activation,
phosphatization, pasivation, DI rinsing, chataphores, UF rinsing and top coat
painting.
Almost all of the sheet metal parts used in the production of tractor are
shaped in the press shop where cutting, drilling, bending, shaping, dampening,
pressing, canal opening, clenching and surface cleaning operations are applied.
Welding and some cutting operations of the sheet metal parts of tractor body
are performed in sheet metal fabrication shop. The main components of tractor
parts such as central housing, hydraulic lifter and other cast and forged
pieces are machined in tractor parts machining shop. After the machining
operations, in order to clean the surface oil and chips, these parts are subjected
to cleaning in the washing machines. In tractor parts painting shop; some cast
parts are painted for obtaining maximum corrosion resistance. Tractor part
painting operations contain; pre-degreasing, degreasing, rinsing, activation,
phosphatization, passivation, DI rinsing, chataphores, dip dying, UF rinsing,
primer coat painting, top coat painting, rework and paint removal operations.
Main parts of the tractor body are assembled in tractor assemble shop.
Helical springs for passenger cars are produced by hot coiling method in
coil springs shop where operations such as annealing, hot coiling, oil hardening, tempering, fracture control, grinding, sandblasting, cold pretreatment,
degreasing, activation, rinsing, zinc phosphate, passivation, DI rinsing are
performed. Conventional leaf springs are produced by applying operations
such as; cutting, central drilling, shaping, bending, annealing, tempering,
sandblasting, assembling, degreasing etc. All types of stabilizer bars are

1796

Babuna et al.

Table 2: Water usage of the investigated plant (m3 d1 ).

Type of usage
Production processes
Cooling water make-up
Boiler water make-up
Domestic
Total

Amount
474
448
50
385
1,357

manufactured for passenger cars and trucks by hot forming, heat treatment
and shot-peening.
The 3- and 4-cylinder engines used in tractors, motor boats and in
industrial generators are produced, tested and adjusted at engine assembly
shop. Degreasing and passivation are the main operations involved in engine
assembly shop.
It must be noted that all the passivation processes applied in the plant
are non-chromium type and not only solvent based paints but also water born
enamels are used in painting operations. Detailed process profile of the plant,
with all process in and outputs including water demands and waste generation,
is described elsewhere.[7]

WATER CONSUMPTION AND QUALITY REQUIREMENTS FOR VARIOUS

WATER USES
Thoughout the plant water is used not only for the production processes
and domestic purposes (water supply for workers and personnel), but also
as cooling water make-up and boiler water make-up. Table 2 presents the
total water consumption of the plant. The total daily water requirement of
the installation may be calculated as 1307 m3 d1 , when boiler water demand
is not considered.
The amount of either continuous or intermittent water requirements
within the production processes are outlined in Table 3. According to the values
presented in the table, a total daily water usage of 474 m3 is involved in the
production. It should be noted that, some production processes necessitates the
usage of deionized water that accounts for more than half of the total water
consumption for manufacturing purposes.
Generally there is a lack of scientific basis for setting the appropriate
quality criteria for water consumption in industrial applications. Thus, specific
demands of the manufacturer based upon practical experience become the decisive factor in defining the water quality requirements. Apart from irrigation,
three different water quality requirements are set by the manufacturer i.e.,
for fresh cooling water inputs and for process waters either deionized or other

Effluent Management for a Metal Finishing Industry

1797

Table 3: Water usage of production processes (m3 d1 ).

Deionized
Production
Steel wheel production
Truck steel wheel
Automobile steel wheel
Tractor production
Press
Sheet metal fabrication
Tractor parts machining
Tractor parts painting
Assembly
Spring production
Coil springs
Leaf springs
Stabilizer bar
Engine production
Engine assembly
Total

Other

Continuous Intermittent Continuous Intermittent Total

30
53

4
6

25
28

9
8

68
95

73
19

1
0.5

47

0
1
4
21
18

0
1
4
142
37.5

20
33

0.9
2

28
28

1
2
0

49.9
65
0

156

12
76

228

14

12
474

type. Table 4 summarizes the relevant quality requirements for different type
of water uses in the installation under investigation. As may be noted from
the table, total dissolved solids, (TDS), either directly measured or expressed
in terms of conductivity level is the sole quality parameter considered, with
the assumption that water will be free of all other organic and/or particulate
impurities. The specified conductivity level varies in a wide range from 10 to
2000 S cm1 , depending on the type of particular use.

WASTEWATER GENERATION AND DIFFERENT TYPES

OF PROCESS WASTEWATERS
Process wastewaters of 425 m3 d1 together with a cooling water discharge
of 112 m3 d1 and a domestic effluent of 385 m3 d1 are generated in the
Table 4: Quality requirements for different water uses in the plant.
Water quality for
Irrigation
Class III (suitable)
Class IV (special care is needed)
Fresh Cooling Water
Process Water
Deionized
Other

TDS (mg L1 )

Conductivity (S cm1 )

5251400
14002100
<450

7502000
20003000
<600

<10
<300400

1798

Babuna et al.

Table 5: Total wastewater generation.

Flowrate (m3 d1 )

Source of wastewaters
Process wastewater
Engine production
Spring production
Tractor production
Steel wheel production
Cooling water discharge
Domestic wastewater
Total

2
106
156
161
112
385
922

plant (Table 5). A conventional wastewater characterization is conducted

on all effluent streams originating from different production processes to
find out distinct quality differences.[7] The observed quality differences are
then evaluated in a way to collect and treat the wastewater streams with
similar characteristics separately as part of an optimal recovery and recycle
strategy. Within the context of this fact, process wastewaters are segregated
to identify five different effluent streams, namely cutting oil wastewaters;
dye containing wastewaters; oily wastewaters; general wastewaters; metal
containing wastewaters. The flowrates of segregated process wastewaters are
outlined in Table 6.
It must be noted that both continuous as well as intermittent wastewater
discharges are generated from the production processes. The frequency of
discharges from intermittent sources varies in a wide range of 2 days to 6
months. The characterization of segregated wastewater streams in terms of
relevant pollutant parameters is tabulated in Table 7.[8] It should be noted
that the values shown in the table represent the results of a single sampling
program and therefore are subjected to variation.
When compared with other process wastewaters, metal containing effluents can be characterized with their low organic contents and high zinc

Table 6: Flowrates of process wastewaters (m3 d1 ).

Type of wastewater
Cutting oil containing
Oily
General
Dye containing
Metal containing
Total

Continuous

Intermittent

Total

96
88
74
112
370

3
26
7
5
14
55

3
122
95
79
126
425

1799

(mg L1 )
(mg L1 )
(mg L1 )
(Scm1 )
(mg L1 )
(mg L1 )
(mg L1 )
(mg L1 )
(mg L1 )
(mg L1 )
(mg L1 )

Unit

N.D.: not determined.

pH
COD
TSS
Oil&Grease
Conductivity
Zinc
Total Iron
Ni
Total Cr
Cd
Cu
Fluoride

Parameter

6.41
60
150
N.D.
1850
56.0
1.0
17.3
N.D.
N.D.
N.D.
18.0

Continuous
6.44
<30
125
N.D.
2600
4.0
5.8
1.0
N.D.
N.D.
N.D.
12.0

Intermittent

Metal containing
wastewater

Table 7: Characterization of segregated streams.

9.48
200
420
25
2500
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.

Continuous
10.35
2510
680
430
10000
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.

Intermittent

Oily wastewater

9.97
45
30
<10
1300
0.1
0.2
<0.2
<0.5
N.D.
N.D.
0.5

Continuous
8.52
175
315
<10
6500
1.2
2.2
0.3
<0.5
N.D.
N.D.
3.0

Intermittent

General wastewater

7.1
1575
105
N.D.
5300
0.45
4.2
<0.2
<0.5
<0.2
<0.5
N.D.

Intermittent

Dye containing
wastewater

1800

Babuna et al.

and nickel concentrations. Both continuous and intermittent sources of oily

wastewaters have an alkaline character. Due to the fact that the continuous streams represent the discharges from rinsing operations that take
place after degreasing applications and the intermittent ones are the degreasing bath discharges itself, the intermittent oily wastewaters are more
concentrated.

TREATMENT REQUIREMENTS
On the basis of specific water quality requirements, treatment to be prescribed
for the recovery and reuse of the wastewater should remove all pollutants
inputs associated with the manufacturing processes and lower the TDS level
to a level acceptable for the respective water demand. In this context, the
following preliminary treatment schemes are proposed for process wastewaters, according to the results of a treatability study, not reported in this paper:
(i) Cutting oil wastewaters: Ultrafiltration + Evaporation, (ii) Dye containing
wastewaters: Phase Separation + Chemical Precipitation + Biological Treatment, (iii) Oily wastewaters: Dissolved Air Flotation + Chemical Precipitation
+ pH Adjustment + Biological Treatment, (iv) Metal containing wastewaters:
Chemical Precipitation + pH Adjustment, and (iv) General wastewaters: pH
Adjustment + Biological Treatment.
After the preliminary treatments specific for each wastewater stream, an
advanced treatment unit to meet the process and cooling water requirements
within the context of total recovery and recycle concept is installed for all
wastewater streams. The full treatment system (preliminary + advanced)
envisaged for segregated process wastewaters is schematically illustrated in
Figure 1.

WATER BALANCE
The following key issues are considered while defining the appropriate water
balance for recovery and reuse:
(i) The water requirement for contact domestic usage is supplied from tap
water.
(ii) Treated cooling water discharge is primarily used to meet the cooling
water requirement.
(iii) In summer and favorable wheater conditions, the treated domestic
wastewater is used for irrigation, after passing through biological treatment, filtration and subsequent disinfection.

1801

Figure 1: Schematic process diagram for process wastewater streams.

1802

Babuna et al.

Table 8: Water input and outputs within production facilities.

Water requirement (m3 d1 )

Losses [evaporation, transportation etc.] (%)
Wastewater generation (m3 d1 )
242

Domestic

Process

Cooling water

385
0
385

474
10.3
425

448
75
112

m3 d1 of which is DI.

(iv) In all other periods (winter conditions), the effluent of the domestic
wastewater treatment plant is directed to the central advanced treatment
facility for recovery and reuse in plant operations. This treated wastewater is used primarly as process water, then as cooling water input and
finally as deionized process water.
(v) A portion of the treated domestic effluent is directly used in non-contact
facilities such as toilet flushing.
The water balances defined for both summer and winter conditions are
outlined in Figures 2 and 3. Two significant factors must be envisaged for
establishing water balance and evaluating the concept of zero discharge. The
first factor relates to water losses associated with in-plant activities, due
to evaporation, transportation, etc. These losses are calculated to vary, as
shown in Table 8, from around 10% for process water to 75% for cooling
water.
The second factor involves losses associated with the treatment of the
generated wastewater flows, as evaporation, formation of sludge and/or brine
etc. For the specific treatment scheme designed for the plant in this study such
losses were evaluated, as listed in Table 8, to account for around 90 m3 d1 or
10% of the total daily wastewater flow. On the one hand these losses are quite
important in setting the correct balance between recovery and demand and on
the other hand, they challenge the validity of the zero discharge concept. In
fact, a careful look at the reclamation system advocated for the plant would
show that 90 m3 d1 of untreatable residues, mostly in liquid form (brines),
have to be disposed of from the plant premises, not perhaps to adjacent
receiving waters, but to authorized sites for final disposal. This situation
requires an in-dept review of the zero discharge concept which finally consists
of dealing with TDS disposal and this parameter may be quite acceptable in
the environment when there is acceptable proof that it may be safely diluted
either on site or else at the final receiving medium. These observations seem
to provide the basis for changing the conventional understanding of zero
discharge towards a much more meaningful and manageable zero pollutant
discharge concept.

1803

Figure 2: Water balance for summer and favorable weather conditions.

1804

Figure 3: Water balance for winter conditions.

Effluent Management for a Metal Finishing Industry

1805

Table 9: Water input and outputs within treatment facilities.

Source
Domestic
Summer
Winter
Process
Cutting Oil
Oily
General
Dye
Metal
Cooling Water
Total

Wastewater
generation
(m3 d1 )

Treatment
units

385
385

BT+F+D
BT+F+D+AT

3
122
95
79
126
112
922

UF+E
DAF+CP+BT+AT
BT+AT
PS+CP+BT+AT
CP+AT
IE

Treatment losses
(%) [evaporation,
sludge and brine
formation etc.]

Treated
wastewater
(m3 d1 )

5
10

366
346

100
10
10
10
10
67

110
86
71
113
105
831 (851 )

Summer conditions, BT = biological treatment, F = filtration, D = disinfection, AT = advanced

treatment, UF = ultrafiltration, E = evaporation, DAF = disolved air flotation, CP = chemical
precipitation, PS = phase seperation, IE = ion exchange.

CONCLUSIONS
A large metal finishing industry is investigated in detail in terms of evaluating
the technical applicability of zero discharge conditions. The results of the
study clearly indicates that evaluation of wastewater management drastically
changes for total recovery and recycle and involves the total dissolved solids
as the significant parameter. Removal of other polluting parameters such
as COD, oil and grease, heavy metals become technically and economically
trivial compared to TDS balance. Available technology removes TDS with high
residue fraction and further reduction of the residue volume becomes totally
prohibitive as far as the cost involved.
The resulting evaluation shows that the concept of zero discharge needs
to be reformulated in terms of major pollutants of concern and implemented
as zero pollution discharge, allowing this way TDS built up and discharge of
treated effluents with a TDS content slightly higher that the available water
supply.

ACKNOWLEDGMENTS
This project was sponsored by Uzel Machinery Industry as an Istanbul
Technical University Development Fund Project (Project No: 2001/01/23).

REFERENCES
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ASCE 2005, 131 (5), 676691.

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Babuna et al.

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California strictest requirements for wastewater reuse. Water Sci. Technol. 1995, 31
(12), 399408.
3. Klinker, R.T. Successful implementation of a zero discharge program. Tappi J. 1996,
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7. Orhon, D.; Germirli Babuna, F.; Kabdasl, I.; Tasl, R.; Dulkadiroglu,
H.; Dogruel,

S.; Olmez,
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8. Orhon, D.; Germirli Babuna, F.; Kabdasl, I.; Dulkadiroglu,

H.; Dogruel,
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