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
• Growing population and industry
Availability • Climate change and draught

• Deteriorating water quality

Quality
• Increased industrial pollution

• Stricter regulation on discharge/withdrawal

Environmental • Water reuse incentives and mandates

• Energy to increase ~30% by 2030

Energy
• Demand for water to increase ~40%

Growing water scarcity and impairment

Types of Reuse

Urban Reuse Industrial Reuse

• Irrigation of parks, highway • Cooling water
medians, golf courses, etc. • Boiler make-up water
• Commercial uses such as vehicle • Industrial process water
washing, window washing, etc.
• Fire protection Agricultural reuse
• Dust control and concrete
production Environmental and recreational
• Toilet and urinal flushing
• To create, restore, and/or
• Construction water enhance wetlands
Groundwater recharge • Recreational and aesthetic
impoundments eg. Ornamental
• Aquifer reinjection ponds
• Subsurface infiltration
• Surface infiltration Reclaimed wastewater is an increasingly
important source of supply
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 GE Water’s UF/MBR Membrane
Technology Applications

Core
Membrane
Technology

Industrial Industrial
Drinking
Sewage UF Pre- Waste-
Water
treatment Water
• Municipal Water • Municipal Sewage Make-up water for: • Membrane Bioreactor
• Marine & Defence • Water Reuse • Boiler feed • Tertiary filtration
• Consumer (Retail) • Land Development • Cooling towers • Water reuse
• Marine & Defence • Process water
ZeeWeed Technology
MBR (Membrane Bio Reactor) &
Tertiary Treatment
ZeeWeed® MBR Simplified Treatment Process

High Quality
Effluent for
RO Feed
Wastewater

ZeeWeed® Tertiary Filtration Process

 ZeeWeed® MBR

Filtrate
Influent 10,000 to (Effluent)
15,000 mg/l

Bioreactor Membrane
(liquid/solids separation)

Hi-Rate Biological Treatment Absolute / Positive Filter

• large capacity throughput • high degree of biomass/solids control

• compact footprint • consistently high effluent quality

• lower operator attention - less

• advanced treatment

• simpler, more reliable process

components
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ZeeWeed® MBR Technology
• Immersed
• Hollow fiber
• Outside-in
• Ultrafiltration (UF)
• PVDF (chlorine and oxidant-resistant)
polymer

0.04 µm 9
ZeeWeed = Consistent High Quality Effluent
Achievable ZeeWeed Treatment 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

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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
Specifics of Industrial Wastewater Reuse
Treatment
• 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
Automotive Industry
Wastewater Reuse
 Automotive WW Treatment

GM Tonawanda, NY, USA Ford Hermosillo, Mexico

SMART Car, Hambach, France 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 process
Design 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 process
Design 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

UF system performance data

Secondary Treated effluent,

effluent to UF RO feed
BOD (mg/L) 50 <5

TSS (mg/L) 200 <1

Turbidity (NTU) 25 < 0.1

SDI (-) N/A < 3.0

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

Cassette Fully Restored After Recovery Cleaning!

India Refinery Projects
EIL – Engineering Consultant

Influent Reuse
API/TPI/DAF SBR Membrane Bio Reactor
MBR Case Study: Refinery Wastewater
BORL Bina
Treatment of refinery
Customer
wastewater for reuse in
Challenge
process

Application Wastewater Reuse

Industry Refinery

Capacity 9.0 MLD

Location Bina, Madhya Pradesh, India

Year of Effluent
2008 Parameter Influent
Commissioning (Design)
System ZW MBR BOD 50 <5
COD 300 <20*
ZW 500 D Hollow fiber
Membranes TSS 100 <1
Outside- in

Partner HDO FOG 10 0

P 5 <1
HPCL Refinery
Owner Name HPCL
Location: Mumbai
System Type: ZeeWeed® MBR
Membrane Type: ZeeWeed® 500
Flow Rate: 7.2 MLD

Feed Source: Refinery Wastewater

BOD < 5 mg/L

COD < 20* mg/L
GE’s Discharge TN* < 7 mg/L
Requirement: Turbidity < 1NTU
And other parameters

Process: Nitrification/De-nitrification
Commissioned: 2010
HMEL Refinery
Owner Name HMEL Refinery
Location: Punjab
System Type: ZeeWeed® MBR
Membrane Type: ZeeWeed® 500
Flow Rate: 12 MLD

Feed Source: Refinery Wastewater

BOD < 5 mg/L

COD < 20* mg/L
GE’s Discharge TN* < 7 mg/L
Requirement: Turbidity < 1NTU
And other parameters

Process: Nitrification/De-nitrification
Commissioned: 2012
India Petrochemical Wastewater
Reuse
Reliance 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’s
Beverage 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 Rico
Soft 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 Bioreactor
• 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

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
 Conclusions
Demands
Exist for wastewater reuse in each type of industry
Immersed hollow fiber membranes fit the need
To 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?