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Technology Solutions For Water Reuse

Technology Solutions For Water Reuse

1. Industrial water reuse key technology

2. Secondary, Tertiary Applications

3. Zero Liquid Discharge

4. Flue Gas Scrubber - Metals

5. Case Histories

Secondary TertiaryScrubber

WATER USERS

Equalization, Pretreatment

BOILERS, COOLING SYSTEMS, PROCESSES

Secondary/TertiaryPRIMARY

INFLUENT

SLUDGE DEWATERING

RIVER

What key technology enables water reuse?

Separations Technologies

Always in Combination

Preconditioning (MF, MMF, Chemical)

Membrane Systems (RO, NF, UF, MF)

Electro Dialysis Reversal (EDR)

Zero Liquid Discharge (ZLD)

DAF / EAF (Entrapped Air Floatation)

Membrane Bio Reactor (MBR)

Media Filters

Mem-Chem Enhancements

Technology exists to reuse water

Inorganic Waste Organic WasteHeavy Metals /Ionic Sink/Complex

UF + ROUF + EDR

MBR Evap / ZLD

Reverse Osmosis

Membrane Configurations for Reuse

Spiral wound/tubular: best suited to NF/RO

Hollow fiber: best suited for MF/UF

Sand filtrationSand filtration

MicrofiltrationMicrofiltration

UltrafiltrationUltrafiltration

NanofiltrationNanofiltration

Reverse OsmosisReverse Osmosis

0.0001 0.001 0.01 0.1 1 10 100mm

Conventional: Best suited Roughing

Increasing pressure requirements

UF Membrane Configurations

Spiral

Inside OutPressure Fiber Out side In

Vacuum PlateTubular

Quality Required by the Effluent Supplied

Pressure Fiber

Waste Water Leader–The Industrial-Strength Solution

Immersed

Hollow fiber

Outside-in

Ultrafiltration (UF)

PVDF (chlorine and oxidant-resistant) chemistry

Absolute Barrier - <3 SDI

Reinforced Membrane Fibre

The membrane can be divided

into three parts:

•Membrane

•Support Braid

•Lumen Performance Parameters

pH 5-9.5

Temp <40 C

Free Oil/Grease 0.0 ppm

ZeeWeed 500 Hollow Fibre UF How Does It Work

Z-MOD™ Effluent Quality

ZeeWeed® 500 Series UF for RO PretreatmentProvides consistent effluent quality everytime!

•BOD < 2 mg/L•TSS < 2 mg/L•TN < 3 mg/L*•TP < 0.05 mg/L*•Turbidity < 0.2 NTU

* With appropriate biological design and/or chemical addition

Secondary Effluent Recycle

Secondary Effluent Recycle

Primary Effluent

Boiler Feed

CIP HotCooling Tower

HygieneProcess Make Up

Primary Waste Treatment

Permeate

Indirect Contact

Flow: >50 gpm>500 <10,000 mg/l COD< 100 mg/l TSS continuous< 500 mg/l TSS Spikes< 2,000 mg/l TDS< 20 mg/l FOG>100 mg/l BOD

Secondary Effluent

Target Water Costs >$4.00/kgal (3.78m3)OBJECTIVE: remove organic* and ionic impurities; recover water, reduce waste volume

MBR RO

Post API/DAFfree oil or TSS removal

Membrane Bioreactor (MBR)

ActivatedSludgeProcess

MembraneFiltration

MBR

Stable BiologicalTreatment Process

Absolute SolidsSeparation

ZeeWeed® MBR System

ZeeWeed® 500 Membrane Cassettes

Permeate Header

Biological Reactor

Air Header

Permeate Pump Air Blower

Control Panel

Conventional AS Process

ActivatedSludge

SecondaryClarifier

SandFilter

PrimaryClarifier

SludgeDigestion To Sludge

Dewatering

ActivatedSludge

To Sludge Dewatering

ZeeWeed® MBR Process

Conventional Activated Sludge vs. MBR

Wastewater strength – effluent requirements and related processes

Wastewater strength (organic load)weak strong

rough

pure

effluentrequire-ments

anaerobic

aerobic (C/N/P) removal

aerobic (C) removal

anaerobic pre-treatmentaerobic (C/N/P) polishing

IndustrialWastewater Treated

Effluent

ProcessBlower

AerobicBioreactor

Air ScourBlower

Recirc Pump

UF ProcessPump

Waste Sludge

Caustic

Phosphoric Acid

ZeeWeed® MBR Typical Process Flow Diagram

Key ZeeWeed® MBR Parameters

HRT of 4-8 hours

SRT of 15-365 days

MLSS of 8-12,000 mg/L (3 to 5 times that of conventional AS plants)

Stable effluent quality

Upset resistant

Reuse DriversRequirements for reuse (now or in future) or direct discharge are primary drivers • Eliminate non-compliance due to

upsets • High purchase or discharge costs• Scarcity or allocation

Reducing BOD surcharges are secondary drivers • Most times meeting sewer use limits

can be done less expensively with MBR• Permit requirements

Space constraints • Most Industrial sites are space

challenged and nothing else will fit!

Other MBR DriversReliable Performance –

-Independent of sludge settling characteristics

Better control of biological process

100% TSS Removal

Year-round nitrification - even in cold climate

Readily adaptable for very high TN/TP reduction

Highly aerobic – no offensive odor (compared to anaerobic)

Best Available Technology for Water Reuse

Compact : Smaller bioreactor, no clarifiers, no sand filters

Ideal for Staged Expansion

Adaptable to existing tanks (minimize civil works)

Significant Footprint Reduction

Conventional plantMembrane bio-reactor plant

Syndial – Porto Marghera

Upgrade of an existing wastewater treatment plant dedicated to the petrochemical facility Ethylene/PVC

Plant was originally built by Lurgiin the 1970s

• April 1998: new Ronchi-Costa legislation mandated stricter effluent limits for industries in the Venice area

• 2003: Syndial requested a bid for the upgrade to major Italian contractors

• Syndial piloted membranes were the best solution and updated the bid to require membranes

Syndial – Biological Tanks

Syndial – ZW 500d Train

Syndial – Porto Marghera

10.14 MGD1,600 m3/hAverage Hourly Flow

12.55 MGD

10.14 MGD

1,980 m3/hDesign Flow

38,400 m3/dAverage Daily Flow

Influent Flow Summary

1,077,220 ft2100,077 m2Total surface area8# trains

44# elements / cassette

340 ft231,59 m2Surface area / element

9# cassettes / train

ZeeWeed® 500dType of filter elements

Process Configuration

Syndial – Porto Marghera

≤ 120 µg/lCOD≤ 0.3 µg/lNitrogen as Nitrate≤ 0.5 µg/lNitrogen as Ammonia ≤ 10 pg/l Total Nitrogen≤ 1 mg/lSuspended Solids, mg/L

Treated Water Quality

Super RO influent quality

COD Reduction

0

1

10

100

1000

10000

0 5 10 15 20 25 30 35

Time (d)

CO

D in

fluen

t; C

OD

effl

uent

(mg·

L-1);

CO

D lo

ad (k

g·m

-3·d

-1)

0

10

20

30

40

50

60

70

80

90

100

MLS

S (g·L

-1);C

OD

removal (%

)

COD influent COD effluent COD load MLSS COD remova l

Tertiary Effluent Recycle

Secondary Effluent

Boiler Feed

CIP HotCooling Tower

HygieneCIP Cold

Waste TreatmentClarifier

Permeate

Indirect Contact

Flow: >50 gpm<200 mg/l COD< 50 mg/l TSS continuous< 150 mg/l TSS Spikes< 2,000 mg/l TDS0.0 mg/l FOG<50 mg/l BOD

Target Water Costs >$4.00/kgal (3.78m3)OBJECTIVE: remove organic* and ionic impurities; recover water, reduce waste volume

UF RO

Post biox final clarifier

Tertiary Effluent

MBR vs. Tertiary Treatment

MBR Simplified Treatment Process

Tertiary Filtration Process

Wastewater

High Quality Effluent forRO Feed

ZeeWeed® Tertiary Filtration PFD

Inlet Water

Reject NeutralizedWaste to Drain/Sewer

Drain/Recirculation

Pump

Air ScourBlower

NaOH SodiumBisulphite

Optional for Neutralization

Permeate to TreatedWater Storage

Permeate/Bakcpulse

PumpStorage

Tank

BackpulseTank

NaOCl Citric Acid

Influent From

Secondary Clarifier

Conc. To Bioreactor

PEMEX Refinery, Mexico

Design WW flow rate of 300 L/s (7 MGD)Treatment includes:

• Dissolved air flotation• Conventional Biological Treatment• ZeeWeed Tertiary Filtration• Reverse Osmosis

Overall water recycle efficiency is approximately 70% based on RO permeate

• One of Mexico’s largest refineries (173,200 bpd)

• Located in Minatitlan, Mexico

• WW treatment allows for recyclePEMEX Minatitlan

PEMEX Refinery, MexicoZeeWeed® system design:

Peak Flow – 300 L/s (~ 6 MGD)Recovery- 90 to 95%7 parallel trains of ZW500b

(6 operating + 1 standby)11 cassettes per train

(expandable to 15)

Effluent Quality Requirements:TSS < 1 mg/lTurbidity < 0.1 NTUSDI < 3

PEMEX – Flow Diagram

RefineryWastewater

333 Lps

300 Lps< 0.2 NTU

< 3 SDI

RO Permeate240 Lps

for Recycle toRefinery

UFPermeate

UFReject33 LpsZeeWeed® UF Operating at 90 % Recovery

8 Trains of 11 cassettes of ZW500b Elements

Refinery

Oil/WaterSeparator

Bioreactor

SecondaryClarifier

Reverse OsmosisSystem Operating at

80 % RecoveryRO

Reject60 Lps

PEMEX Refinery, Mexico

ZeeWeed Process Trains

ZeeWeed Building

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

Cassette Fully Restored After Recovery Cleaning!

NO Discharge –RO’s Saved!!

Refinery / Petrochemical Water Reuse

ZW + RO tertiary0.35M3.32006Sasol Secunda, South Africa

ZW + RO tertiary4.0M3.52006ENI R&M, Taranto, Italy (R)

0.76

5.7 ADF

6.9 MDF

0.16

6.8

1.3 Ph.1

5.28 Ph.2

1.9

1.9

Size (MGD)

ZW + RO MBR2.74M2007ENI, Gela, Sicily (R)

ZW + RO MBR2.74M2007ENI Priolo, Sicily (R)

ZW + RO tertiary4.4M2001PEMEX, Minatitlan, Mexico (R)

ZW + RO MBR2004Borsodchem, Hungary (R)

0.2M

2.6M

5.6M

Sales$M

ZW + RO tertiary2004Yanshan Petrochemical, China (P)

ZW + RO MBR2005Formosa Petrochemical Corp., Taiwan (P)

ZW tertiary 2004Syndial Manfredonia, Italy (R)

Startup

ApplicationLocation

Zero Liquid Discharge

Brine Concentrator/Crystallizer PFD

Auburndale Power Plant

Comparison of Traditional and Evaporative Produced Water Treatment Approaches

Traditional Approach

Evaporative Approach

Simplified Vapor Compression Falling Film Evaporator System

Suncor Firebag Stage 2 Evaporators

Typical Heavy Oil Zero Liquid Discharge Crystallizer System

Economic Analysis Summary (WLS / WAC vs. Evaporation)

When compared to WLS / WAC / OTSG, the evaporator / drum boiler approach resulted in:

• 6% lower operating cost over life of plant• 10% lower total installed costs for

ENTIRE facility• 5 year and 10 year NPV savings of 11%

and 12%, respectively, EXCLUDING lost opportunity credit for higher on-stream availability

• 2-3% higher on-stream availability• Significantly lower operational labor and

maintenance requirements for evaporator and boiler

• 6 month shorter scheduleTotal Deer Creek

Modularized General Arrangement

Oil Sands - Mature Fine Tails

BOD / COD- 30/100 mg/l

Direct UF vs MBR - MFT

HFUF to RO

HFUF to RO

Case Study – Doswell Power Overview•The Doswell Combined Cycle power plant generates 665 MW. •The plant is in a water short area requiring recycle/reuse of all wastewater.•ZLD operates on EDR & RO brine concentrate.

Performance•The EDR, RO, ZLD systems met performance criteria.•Using EDR, RO before ZLD saved the client $900K in capital costs and $700/day in operating costs vs a system without the use of membrane systems.

Doswell Power PFD

250gpm - Thru 6 Steps - 0.2gpm

Advanced Biological

AdvancedBiological Treatment

Inorganics and Metals Removal

Advanced Biological Metals (ABMet®) Removal Process

Removes metals and inorganics to below non-detectable levels

Utilizes a simple and controlled biological reduction and precipitation process

Keeps metal particulates inside the system until recovery

Ideal for use in scrubber water reuse

Best Available Technology99+% Removal of:

• Selenium• Arsenic• Mercury• Chromium• Cadmium• Copper• Zinc• Cobalt• Nickel• Antimony• Nitrate

ABMet® Metals Removal

0

1

2

3

4

5

6

Untreated 2 3 4 5 6

Time [weeks]

Ars

enic

, Sel

eniu

m

[m

g/L]

0

2

4

6

8

10

12

Mer

cury

[ug/

L]

Arsenic Selenium Mercury

Revolutionary Biological Design

Uses naturally occurring microbes that grow on the biomatrix to remove metals from wastewater

Site-optimized for different treatment requirements

Controlled precisely and consistently to achieve target levels of contaminant removal

Simple ABMet® System Design

Consists of a series of bioreactors or “cells” each containing a biomatrix for microbial growth and stability

Includes fluidizing and backflushing capabilities for periodic maintenance and for contaminant collection and disposal or recovery

Biochemical Conversions1. Nitrates are converted to nitrogen gas2. Dissolved metals are converted to metal sulfides and are retained

within the system3. Bacteria reduce oxidized forms of selenium to elemental selenium

Lower Costs. Better Results.

Reverse Osmosis($3 - $10/1,000 gal)

Ion Exchange($1 - $3/1,000 gal)

FerrihydritePrecipitation (BDAT)($9 - $15/1,000 gal)

Nanofiltration($3 - $8/1,000 gal)

ABMet®(< $1.00/1,000 gal)

In-Situ

Wetlands(below $2/1,000 gal

Chemical Precipitation($1 - $5/1,000 gal)

TREATMENT COSTHigh Low

High

Low

EF

FEC

TIV

EN

ES

S

Treatment of Petroleum Refinery Wastewater for Metals Removal

Selenium (Se) present in natural crude oil is removed and eventually flows to the stripped sour water waste stream

Refineries are often located in heavily populated areas and are direct dischargers of waste

Regulatory authorities are now pushing limits of < 5 ppb for Se

Power Generation

OverviewOne of the largest power plants in the United States

Flue Gas Desulfurization (FGD) wastewater, contaminated with selenium and other metals, must be treated prior to being discharged to meet environmental requirements

The ABMet® process was selected to biologically remove selenium from wastewaters

North Carolina Utility

Case study:Great White North Refining