Mr. Manish Kharwade - Praj

Zero Liquid discharge
for the Industrial sector
22.04.2014
Major Concerns. . .
Where is the
space for
process
plant???
Reduce Foot Print

Major Concerns. . .
Can I use treated

wastewater
somewhere???
Recycle & Reuse of Treated Wastewater

Major Concerns. . .
Can I avoid liquid

discharge???
Zero Liquid Discharge (ZLD)

Major Concerns. . .
Can I
generate/save
energy???
Energy Recovery & Maximization of Energy Efficiency

Water
&
Wastewater
Solution
Solutions. . .
Selection of Appropriate Technologies
Integrated Design Approach
Solution under one roof

Zero Liquid Discharge. . .
How to Achieve ZLD. . .
STEP 1
Effluent From Process

Plant
Recovery of solvents by using distillation Process

STEP 2
Effluent after
Solvent Recovery
Removal of Organic Matter by Using Anaerobic

Digestion
STEP 3
Anaerobically
Treated Effluent
Removal of Balance Organic Matter by Using Aerobic

Digestion
STEP 4
Treated Effluent
from ETP
Clarification by using, tube settler

/Clariflocculator
STEP 5
Effluent after
Clarification
Further Reduction in TSS by using Filters

STEP 6
Effluent
after Filters
Reduction in Turbidity and SDI by using Ultra

Filtration
STEP 7
Effluent
after UF
Recovery of low TDS Permeate by using RO

STEP 8
High TDS Rejects

from RO
Concentration of RO Rejects by using battery of

evaporators
STEP 9
Separation of salts from Mother Liquor

using Centrifuge Drying of Mixed Salts using ATFD
In case if advance technologies like MBR
is used for the treatment of effluents
then 4th to 6th steps can be eliminated
In case if advance technologies like MBR is used for the treatment of
effluents then 4th to 6th steps can be eliminated
TANK VOLUME
Conventional ASP MBR Process

100% 40%
Key Challenges in ZLD. . .
Efficient Treatment for Reduction of COD & BOD

High Recovery through RO to reduce load on Evaporation
system
Highly Corrosive Effluent
Material Compatibility at Higher Temperature
High Capital Investment
Operating Cost for the treatment
Turnkey Responsibility
How to Address Challenges. . .
Efficient Removal of COD & BOD
- Use of Advance Biological Treatment
High Recovery through RO

- Use of Proper Pre-treatment
- Right Selection of Membranes and RO Configuration
Material Compatibility at Higher Temperature

- Operate Evaporation System at low temperature
High Capital Investment

- Use various combination of Evaporators
Operating Cost for the treatment

- Use innovative approach like TVR or MVR
Solutions. . .
Conventional Falling Film Evaporator

Forced Circulation Evaporator
Forced Falling Film Evaporator
Fluidized Bed Patented Evaporator
Falling Film Evaporator. . .
STEAM
STEAM VAPORS
COND.
FEED
Features and Limitations. . .
Better Heat Transfer Not suitable at higher

Coefficient. suspended solid concentration
and higher viscosity.
Low Power consumption
.
Distribution system is critical
Can be started up and can lead to tube fouling in
quickly and changed to absence of adequate wetting
cleaning mode . rate.
Useful in heat sensitive
Frequent C.I.P. Required .
chemical solutions
Forced Circulation. . .
VAPORS
STEAM
FEED
CONDENSATE
CONC.
PRODUCT
Features and Limitations. . .
Capable of handling High Capital Investment.
Suspended slurry, Saturated
High Operating Cost.
solution & viscous liquids.
Can be operated with min
temperature differences
between the heating media
and the boiling liquid.
No frequent Scale inside the
tubes.
Can be installed vertically as

well as horizontally.
Forced Falling Film. . .
LIQUOR IN
SHOWER NOZZLE
DISTRIBUTOR
LIQUOR Tube Wall

FILM
FALLING FILM UPPER MAIN LIQUOR BOX
Condensed Steam
Or Vapor On Outside
Wall Of Tube
LIQUOR
VAPOR
Features. . .
All advantages of conventional falling film Evaporation.

Comparatively less problem of tube wetting rate due to
Spraying Nozzles.
Less prone to fouling as compared with Conventional Falling
Film Evaporator.
Flubex. . .
Flubex- Concept
Recirculating fluidized bed

heat exchanger
Evaporation by Flashing in
Vapor Liquid Separator.
Fluidizing medium in Tube.
Self-cleaning action.
Flubex. . .
Flubex. . .
Continuous self-cleaning
action avoid scaling.
No Frequent C.I.P.
Less generation &
disposal problem of C.I.P.
Effluent.
No standby unit required.
Lesser floor space.
Advanced Technology. . .
ECOPHOTOx. . .
Photo - Light (Photon)
Oxidation - Addition of Oxygen
Pollutant and oxidant are elevated to an

activated state wherein the oxidation rate
increases multifolds. As a result, the COD
contributing molecules are broken down,
oxidised and leave the effluent stream in the
form of CO2 and H2O
Complex Organic UV Activation UV Activation

Intermediates CO2+ H2O
Compounds Oxidant Oxidant
What is ECOPHOTOx
It destroys/treats non-biodegradable
organic contaminants present in
wastewater, which are generally
represented as Recalcitrant Chemical
oxygen demand.
It enhances the oxidation rate with the

help of ultraviolet light in presence of
oxidizing chemicals such as hydrogen
peroxide, ozone etc
Praj Industries Ltd www.praj.net 32

What is ECOPHOTOx
Exposing H2O2 to Ultraviolet radiation

generates OH radical.
H2O2 + light energy (hv) - - - - - - -
2*OH
OH radical (hydroxyl radical) is
powerful but relatively non-selective
transient oxidizing species.
*OH has the highest thermodynamic
oxidation potential.
Most environmental contaminants
react 1 million to1 billion times faster
with *OH than with O3 - a
conventional oxidant.

What is ECOPHOTOx
Oxidant Oxidation
Potential
OH 2.80
O(1D) 2.42
O3 2.07
H2O2 1.77
Perhydroxy 1.70
Radical
Permangante Ion 1.67
Chlorine Dioxide 1.50
Chlorine 1.36
O2 Oxidation Potential Unit1.23
- (eV)2

Flubex Installation. . .
MVR Based Evaporator Installation. .
Steam less Evaporation

Stripper for Process
Condensate
Recyclable quality of
process condensate
Concentrate having high
calorific value use as a
fuel
Evaporator Plant Installation. .
Recovery of Globur
Salts (Na2SO4.10 H2O)
Selling at handsome
price
Smart Payback
3 Effect TVR Based MEE. .
Recovery of NaCl Salts

Selling at handsome
price
Smart Payback
Other Technologies in Basket. .
Advanced Anaerobic Digestion

Advanced Aerobic System (MBBR, SBR, MBR etc)
All types of Membrane Applications
Ozonation
Solution under One Roof. .
More than 600 references in 50

countries
Thank you
Manish Kharwade
[email protected]
Praj Industries Ltd www.praj.net

Mr. Manish Kharwade - Praj

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Zero Liquid discharge

for the Industrial sector

Reduce Foot Print

Can I use treated

Recycle & Reuse of Treated Wastewater

Can I avoid liquid

Zero Liquid Discharge (ZLD)

Energy Recovery & Maximization of Energy Efficiency

Selection of Appropriate Technologies

Integrated Design Approach

Solution under one roof

Effluent From Process

Recovery of solvents by using distillation Process

Removal of Organic Matter by Using Anaerobic

Removal of Balance Organic Matter by Using Aerobic

Clarification by using, tube settler

Further Reduction in TSS by using Filters

Reduction in Turbidity and SDI by using Ultra

Recovery of low TDS Permeate by using RO

High TDS Rejects

Concentration of RO Rejects by using battery of

Separation of salts from Mother Liquor

Conventional ASP MBR Process

Efficient Treatment for Reduction of COD & BOD

High Recovery through RO

Material Compatibility at Higher Temperature

High Capital Investment

Operating Cost for the treatment

Conventional Falling Film Evaporator

Better Heat Transfer Not suitable at higher

Can be installed vertically as

LIQUOR Tube Wall

FALLING FILM UPPER MAIN LIQUOR BOX

All advantages of conventional falling film Evaporation.

Recirculating fluidized bed

Oxidation - Addition of Oxygen

Pollutant and oxidant are elevated to an

Complex Organic UV Activation UV Activation

It enhances the oxidation rate with the

Praj Industries Ltd www.praj.net 32

Exposing H2O2 to Ultraviolet radiation

Praj Industries Ltd www.praj.net 33

Praj Industries Ltd www.praj.net 34

Steam less Evaporation

Recovery of NaCl Salts

Advanced Anaerobic Digestion

More than 600 references in 50

Praj Industries Ltd www.praj.net

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