of 73
8/14/2019 IEI 26-01-2013
1/73
Dr. M. RAMESH KUMAR,
Dept. of Garment and Fashion Technology,Sona College of Technology,
Salem 636 005.
1
TEXTILE INDUSTRY WASTEWATER
TREATMENT - AN OVER VIEW
IEI Salem Chapter on 26-01-2013
8/14/2019 IEI 26-01-2013
2/73
SOURCES OF WATER
The worldswater is found in oceans and seas,lakes and reservoirs, rivers and streams, glaciers
and snowcaps in the polar regions in addition to
ground water.
Distribution of water Percentage ofwater
Oceans and Seas 96 - 97%
Glaciers and Polar
icecaps
2 - 3%
Fresh water < 1%2
8/14/2019 IEI 26-01-2013
3/73
3
ReservoirVolume
(cubic km x
10,000,000)
% of Total
Oceans 1370 97.25
Ice Caps/Glaciers 29 2.05
Deep
Groundwater
5.3 0.38
Shallow
Groundwater
4.2 0.30
Lakes 0.125 0.01
Soil Moisture 0.065 0.005
Atmosphere 0.013 0.001
Rivers 0.0017 0.0001
Biosphere 0.0006 0.00004
Inventory of Water at the Earth's Surface
8/14/2019 IEI 26-01-2013
4/73
4
Water Allocation Priority
8/14/2019 IEI 26-01-2013
5/73
5
Indias Water Demand
Present water demand in India - 703 km3
/year. For domestic use43 km3/year
For industrial use37 km3/year
For agricultural use550 km3/year
India receives annual precipitation of
about 4000 km3
Only 35% of surface water is
utilizable.
8/14/2019 IEI 26-01-2013
6/73
6
Water Pollution
Discharge of partially or untreatedindustrial effluent.
Discharge of untreated domestic
sewage.
Mismanagement practice of solid
wastes. Unscientific use of synthetic fertilizers.
8/14/2019 IEI 26-01-2013
7/73
Effluent Water is referred as wastewater (effluent) when it is
impaired by anthropogenic contaminants
Domestic Effluent
Biologically Active
Effluents
Landfill Leachates
Water Disinfection
Malodourous
Effluents
Industrial Effluent
Ammoniacal Wastes
Coloured Effluents
Hazardous Effluents
Malodourous Effluents
Recalcitrant Effluents
7
8/14/2019 IEI 26-01-2013
8/73
Polluting Industries
Pulp and Paper
Industries
Dairy Industries
Slaughter Houses
Ceramics Industry
Fruits and Vegetables
Processing
Fish Processing and
Canning
Metal Plating Industries
Paint Industries
Pharmaceutical Industries
Refineries
Petrochemical Complexes
Textile Industries
8
8/14/2019 IEI 26-01-2013
9/73
Discharge of Textile Industry Effluent
9
8/14/2019 IEI 26-01-2013
10/73
10
Textile Industries
Complicated Industry among other
manufacturing Industries. Second largest Employment Generator.
Textile account for
- 17 % of Export Earnings
- 14% of Indias industrial production
- 4% to GDP
Third largest polluter in the world.
Erode, Tirupur and Karur are hub of textile
sector.
8/14/2019 IEI 26-01-2013
11/73
Textile Industries.
More than 1 lakh commercial dyes areavailable.
Dye annual production approximately10,00,000 tons.
Azo dyes account for 60 to 80% of the dyesconsumed in textile processing
About 5200 organized bleaching and dyeing
industries are in India & more unorganizedindustries are also available.
50% industries at Tirupur, Karur and ErodeDistricts
11
8/14/2019 IEI 26-01-2013
12/73
Government Action against Polluting
Industries
12
8/14/2019 IEI 26-01-2013
13/73
Wastewater Issues
8/14/2019 IEI 26-01-2013
14/73
Wastewater Issues
8/14/2019 IEI 26-01-2013
15/73
Need for treatment....,
15
8/14/2019 IEI 26-01-2013
16/73
Need for treatment....,
16
8/14/2019 IEI 26-01-2013
17/73
Need for treatment....,
17
8/14/2019 IEI 26-01-2013
18/73
Fresh Water Scarcity
Huge demand for fresh water due to rapid
increase in population, coupled withcivilization and expanding economy of thecountry-led to the depletion of ground and
surface water.Poor Rainfall- lesser recharge of aquifer
Availability of fresh water in the globe isfixed & limited
Hence the fresh water requirement hasbecome a matter for serious concern. Thereis a huge demand for fresh water.
8/14/2019 IEI 26-01-2013
19/73
Major Classification of Textile
Dyeing Industries
- Woven fabric dyeing industry
- Knitted fabric dyeing industry
- Yarn dyeing industry
- Printing industry
19
8/14/2019 IEI 26-01-2013
20/73
Woven fabric dyeing industry
20
8/14/2019 IEI 26-01-2013
21/73
Knitted fabric dyeing industry
21
8/14/2019 IEI 26-01-2013
22/73
Yarn dyeing industry
22
8/14/2019 IEI 26-01-2013
23/73
Printing industry
Rotary Printing
23
8/14/2019 IEI 26-01-2013
24/73
Environmental Problems due to
Textile Industries
Even though Textile Industry plays an important role inIndian economy in multiple ways it also causes majorenvironmental impact.
Erode, Tirupur and Karur districts are hub of textile
industries in which more than ten thousand small andmedium scale industries are functioning.
This super power continuously threatens the livelihoodby discharging the effluent into river (Cauvery, Bhavani
and Noyal) & near by canals (Kalingarayan canal )
Hence, proper treatment is essential for a healthyatmosphere.
24
l ifi i f h d
8/14/2019 IEI 26-01-2013
25/73
Classification of Wastewater Treatment Methods
Bioaugmentation
Activated sludge
Extended aeration
Anaerobic processes
Rotating biological
contactors
SBR and trickling filters
Adsorption, Filtration
Stripping/
Sedimentation
Membranetechnologies
Chemical Oxidation/
Precipitation/Coagulation
air flotation/Flocculation
Hydrolysis/Neutralization
Solvent Extraction
Ion Exchange
CHEMICAL PHYSICAL BIOLOGICAL
INDUSTRIAL WASTEWATER TREATMENT METHODS
25
Cl ifi i f W T M h d
8/14/2019 IEI 26-01-2013
26/73
Classification of Wastewater Treatment Methods
Bioaugmentation
Activated sludge
Extended aeration
Anaerobic processes
Rotating biological
contactors
SBR and trickling filters
Adsorption, Filtration
Stripping/
Sedimentation
SkimmingMembrane
technologies
Chemical Oxidation/
Precipitation/Coagulation
air flotation/Flocculation
Hydrolysis/Neutralization
Solvent ExtractionIon Exchange
CHEMICAL PHYSICAL BIOLOGICAL
INDUSTRIAL WASTEWATER TREATMENT METHODS
Physical/Chemicalprocesses if chemical
agents as coagulating
agents are added.
26
8/14/2019 IEI 26-01-2013
27/73
Membrane Technology
Micro filtration
Ultrafiltration
Nanofiltration
Reverse Osmosis Membrane
27
8/14/2019 IEI 26-01-2013
28/73
Reverse Osmosis
28
8/14/2019 IEI 26-01-2013
29/73
RO Membrane Technology
29
8/14/2019 IEI 26-01-2013
30/73
KOCH MEMBRANE
30
8/14/2019 IEI 26-01-2013
31/73
ROSA MEMBRANE ( FILMTEC)
31
8/14/2019 IEI 26-01-2013
32/73
MEMBRANE SPECIFICATIONS
PARTICULARS
KOCH
MEMBRANE
ROSA
MEMBRANE
Membrane Thin Film
Composite
Filmtech
Materials of
Construction
Polyamide Polyamide
Software ROPRO ROSA
Pore size 0.1 Micron 0.1 Micron
Range of operating
pressure
30 - 40 bar 30 - 40 bar
Temperature 30 400C 30 400C
pH 2 11 2 11 32
8/14/2019 IEI 26-01-2013
33/73
Advantages of RO Membrane
Highly efficient High recovery%
Lower rejection%
Lower maintenance cost Lower power consumption
Lower pressure
Cost effectiveness Easy to operate & Maintain
Wastewater can be reused in Large
proportion 33
INDUSTRIAL WASTEWATER TREATMENT METHODS
8/14/2019 IEI 26-01-2013
34/73
Conventional
Treatment
High-qualityTreatment
Wastewatertreatment
process
Its a combination of
physical, chemical, and
biological processes
PRELIMINARY
TREATMENT
PRIMARY
TREATMENT
SECONDARY
TREATMENT
ADVANCED
TREATMENT
Feed wastewater
stream
To discharge or
reuse/recycling
INDUSTRIAL WASTEWATER TREATMENT METHODS
34
INDUSTRIAL WASTEWATER TREATMENT METHODS
8/14/2019 IEI 26-01-2013
35/73
Removal of grit, debris and excessive
amounts of oils or greases.
Wastewater pretreatment plant.
Wastewatertreatment
process
Its a combination of
physical, chemical, and
biological processes
PRELIMINARY
TREATMENT
PRIMARY
TREATMENT
SECONDARY
TREATMENT
ADVANCED
TREATMENT
Feed wastewater
stream
To discharge or
reuse/recycling
35
INDUSTRIAL WASTEWATER TREATMENT METHODS
8/14/2019 IEI 26-01-2013
36/73
Wastewater
treatmentprocess
Its a combinationof physical,
chemical, and
biological processes
PRELIMINARY
TREATMENT
PRIMARY
TREATMENT
SECONDARY
TREATMENT
ADVANCED
TREATMENT
Feed
wastewater
stream
To discharge or
reuse/recycling
The reached removal is up to
85-95% of BOD and SS &
65% of COD.
36
INDUSTRIAL WASTEWATER TREATMENT METHODS
8/14/2019 IEI 26-01-2013
37/73
Wastewater
treatment
process
Its a combination of
physical, chemical,
and biological
processes
PRELIMINARYTREATMENT
PRIMARY
TREATMENT
SECONDARY
TREATMENT
ADVANCED
TREATMENT
Feed wastewater
stream
To discharge or
reuse/recycling
Removal of :
Additional organic and suspended
solids.
Nitrogenous Oxygen Demand (NOD)
Nutrients
Toxic materials
Also called Tertiary
Treatment
Membrane separation
37
8/14/2019 IEI 26-01-2013
38/73
WASH WATER PLANT TREATMENT SCHEME
PRIMARY TREATMENT (PHYSICO-CHEMICAL)
SECONDARY TREATMENT (BIOLOGICAL)
TERTIARY TREATMENT (PHYSICO-CHEMICAL) UF/RO RECYCLING PLANT
DYE BATH PLANT
FIVE EFFECT FALLING FILM EVAPORATOR
EVAPORATOR AND SALT RECOVERY PLANT
TREATMENT METHOD
38
8/14/2019 IEI 26-01-2013
39/73
SCHEMATIC DIAGRAM OF WASHWATER PRIMARY TREATMENT
RAW EFFLUENT FROM
MEMBER UNITS ( TDS< 2100mg / lit)
PRIMARY OUTLET
TO BIOLOGICAL
TREATMENT
RECEIVING SUMP EQUALISATION TANK
FLASH MIXING TANK
LIME, FeCl2, POLY
CLRIFLOCCULATOR
CLARIFIED EFFLUENT SUMP
THICKENERFILTER PRESS
CENTRIFUGE
SLUDGE SUMP
SLUDGE TO SLUDGE STORAGE YARD 39
8/14/2019 IEI 26-01-2013
40/73
PRIMARY TREATMENT
RECEIVING SUMP Wash water effluent received and screened.
EQUALISATION TANK
The effluent is homogenized with high speedfloating aerators.
FLASH MIXING TANK
Coagulant and flocculent addition, Such asLime , FeCl2 and Poly electrolyte.
40
8/14/2019 IEI 26-01-2013
41/73
41
8/14/2019 IEI 26-01-2013
42/73
42
8/14/2019 IEI 26-01-2013
43/73
43
8/14/2019 IEI 26-01-2013
44/73
44
8/14/2019 IEI 26-01-2013
45/73
SCHEMATIC DIAGRAM OF SECONDARY TREATMENT
(BIOLOGICAL TREATMENT)
FROM PRIMARY OUTLET
NUTRIENTS
RETURN ACTIVATED SLUDGE
AERATION TANK
SECONDARY CLARIFIER
TO TERTIARY
TREATMENT
EXCESS TO THICKENER
AIR SUPPLY
45
8/14/2019 IEI 26-01-2013
46/73
SECONDARY TREATMENT (BIOLOGICAL)
SECONDARY CLARIFIER
The mixed liquor from the biologicalrector is sent to secondary clarifier forsettling the bio mass and a portion is
pumped to biological rector for re-activation.
46
8/14/2019 IEI 26-01-2013
47/73
47
8/14/2019 IEI 26-01-2013
48/73
48
8/14/2019 IEI 26-01-2013
49/73
49
8/14/2019 IEI 26-01-2013
50/73
TERTIARY TREATMENT
To improve the quality of secondary treatedeffluent
By reducing the suspended solids. By reducing the colloidal particles.
By destroying the micro organism.
By reducing the alkalinity.
By reducing the color and metal ions.
50
SCHEMATIC DIAGRAM OF TERTIARY
8/14/2019 IEI 26-01-2013
51/73
SCHEMATIC DIAGRAM OF TERTIARY
TREATMENTFLASH MIXING TANK
LIME, FeCl2, POLY
TERTIARY CLARIFIER THICKENER
SLUDGE SUMP
COLLECTION TANK
DUAL MEDIA FILTER
TO RO PLANT
FILTER PRESS
SLUDGE TO
SLUDGE YARD
FROM
BIOLOGICAL
TREATMENT
51
8/14/2019 IEI 26-01-2013
52/73
52
8/14/2019 IEI 26-01-2013
53/73
53
8/14/2019 IEI 26-01-2013
54/73
54
8/14/2019 IEI 26-01-2013
55/73
55
MEMBRANE BASED RECYCLING
8/14/2019 IEI 26-01-2013
56/73
MEMBRANE BASED RECYCLING
PLANT
ULTRAFILTRATION
It will remove the colloidal particles,silica, suspended solids, biologicalmatters (bacteria, Algae, Fungi) and
also to reduce the total organiccompounds.
56
8/14/2019 IEI 26-01-2013
57/73
UF FEED TANK CIP
ULTRAFILTRATION SYSTEM
PG
PG PT
FT
UF PERMEATE TANK
FT
PG
PG
PG
PT
PT
PT
AV
AV
AV
AV
AV
AV
UF RECIRCULATION
PUMP
BAG FILTER 100
BACK FLUSH PUMP57
8/14/2019 IEI 26-01-2013
58/73
58
8/14/2019 IEI 26-01-2013
59/73
REVERSE OSMOSIS - I
8/14/2019 IEI 26-01-2013
60/73
PG
PRESSURE VESSEL 2
PRESSURE VESSEL 4
PRESSURE VESSEL 5
PRESSURE VESSEL 3
PRESSURE VESSEL 6
PRESSURE VESSEL 7
PRESSURE VESSEL 8
PRESSURE VESSEL 9
PRESSURE VESSEL 13
PRESSURE VESSEL 12
PRESSURE VESSEL 11
PRESSURE VESSEL 10
PG
PG
PG
PG
FROM RO CIP
RO CIP
FT
RO CIP
PG
UF PERMEATE TANK
TO RO II FEED
ANTI SCALANT
HCl SMBS
PRESSURE VESSEL 1
FT
MICRON FILTER 5
MICRON FILTER
10
CIP PUMP
HIGH PRESSURE PUMP
FEED PUMPPERMEATE TO STORAGE TANK
AV
AV
PT
SDI
PT
PT
PT
ORP
60
8/14/2019 IEI 26-01-2013
61/73
61
8/14/2019 IEI 26-01-2013
62/73
H
CI
S
M
BS
A
ntis
ca
le
nt
HPP
Feed
30m3/h
RO Feed
Tank
MCF
HPP HPP HPP
RO Permeate
27 m3/h
(90%)
RO Reject
3m3/h (10%)
MCF
Feed
Pump RO I, 1stArray RO I, 2ndArray RO II, 1stArray RO II, 2ndArray
RO Feed and Permeate
RO flow m/hr
RO Feed Flow - 30.00 m/hr
RO Permeate Flow - 27.00 m/hr
RO Reject Flow - 3.00 m/hr
RO Recovery % - 90.00 %
RO Array Classification
RO Stage I 5 X 6: 3 X 6
RO Stage II 2 X 5: 1 X 5
RO 1, 5 vessels and 3 vessels (48 elements)Stage I, Feed 5 membranes
Stage II, Feed 3 membranes
RO II, 2 vessels and 1 vessel (15 membranes)
Stage I, Feed 2 membranes
Stage II, Reject 1 membrane
No. of RO Elements used
RO Stage I 48 Elements
RO Stage II 15 Elements
Total 63 Elements
62
8/14/2019 IEI 26-01-2013
63/73
63
8/14/2019 IEI 26-01-2013
64/73
64
8/14/2019 IEI 26-01-2013
65/73
65
8/14/2019 IEI 26-01-2013
66/73
66
8/14/2019 IEI 26-01-2013
67/73
Comparison of Raw effluent RO Feed and Permeate
8/14/2019 IEI 26-01-2013
68/73
Parameters Raw Effluent
(ppm)RO Feed (ppm)
RO Permeatevalue
KOCH ROSA
TDS 6080.00 6357.00 110.13 244.28
COD 700.00 50.00 6.61 8.31
BOD 200.00 6.00 4.82 5.52
Cl 3250.00 3380.00 61.64 133.56
Ca2+ 45.00 50.00 0.16 0.54
Mg2+ 25.00 25.00 0.08 0.28
Na+ 2250.00 2363.00 42.75 91.49
K+ 8.00 5.00 0.12 0.69
NH4+ 8.00 0.60 0.03 0.33
HCO3 700.00 300.00 7.27 9.61
SO42- 338.00 350.00 1.08 5.27
NO3 7.80 5.00 0.42 2.02
SiO2 20.50 15.00 0.26 0.42
Comparison of Raw effluent, RO Feed and Permeate
68
Comparison of RO Feed and RO Permeate
8/14/2019 IEI 26-01-2013
69/73
0
1000
2000
3000
4000
5000
6000
7000
RO
PermeateVa
luesinppm
TDS COD BOD Cl Ca2+ Mg2+ Na+ K+ NH4+ HCO3 SO42- NO3 SiO2
Parameters
RO Feed
RO Permeate - ROSA
RO Permeate - KOCH
Comparison of RO Feed and RO Permeate
69
8/14/2019 IEI 26-01-2013
70/73
70
8/14/2019 IEI 26-01-2013
71/73
CONCLUSION
The overall performance of ReverseOsmosis Membranes is better in
Textile industry.
The Reverse Osmosis Membrane
treatment is very effective in Textile
industry. RO membrane was found to be
more efficient and economical.71
8/14/2019 IEI 26-01-2013
72/73
CONCLUSION
90% - 93% of RO Permeate watercan be used for recycling.
Remaining 7% - 10% RO Rejectwater can be sent to Solar
evaporation/Multipleevaporation for salt recovery.
72
8/14/2019 IEI 26-01-2013
73/73
LET US MAKE OUR NATION