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Green Business Options: Zero
Liquid Discharge Solutions for
Industries
By Manish Kharwade
Industries Major
Concerns
© Praj Industries Ltd www.praj.net
Where is the
space for
process
plant???
Reduce Foot Print
Major Concerns. . .
Recycle & Reuse of Treated Wastewater
Can I use treated
wastewater
somewhere???
Major Concerns. . .
Zero Liquid Discharge (ZLD)
Can I avoid liquid
discharge???
Major Concerns. . .
Energy Recovery & Maximization of Energy Efficiency
Can I
generate/save
energy???
Major Concerns. . .
Integrated Design Approach
Selection of Appropriate Technologies
Solution under one roof
Some Solutions. . .
Various Technologies
Floating Matter
RemovalOil & TSS Removal TSS Removal Organic Matter Removal
All types of Membrane
Applications
All types of Strippers &
EvaporatorsDryers & Crystallizer
Various Types of
Evaporators
© Praj Industries Ltd www.praj.net
Falling Film Evaporator. . .
Forced Circulation. . .
FEED
CONC.
PRODUCT
CONDENSATE
STEAMVAPORS
Forced Falling Film. . .
SHOWER NOZZLE
DISTRIBUTOR
LIQUOR Tube Wall
FILM
Condensed Steam
Or Vapor On Outside
Wall Of Tube
LIQUOR
VAPOR
LIQUOR IN
FALLING FILM UPPER MAIN LIQUOR BOX
Flubex. . .Flubex- Concept
Recirculating fluidized bed heat
exchanger
Evaporation by Flashing in Vapor
Liquid Separator.
Fluidizing medium in Tube.
Self-cleaning action.
Flubex. . .
• Continuous self-cleaning action
avoid scaling.
• No Frequent C.I.P.
• Less generation & disposal
problem of C.I.P. Effluent
• No standby unit is required
• Lesser floor space
Multi Effect Evaporation
Thermal Vapor Recompression
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• Vapors are compressed by means of steam jet ejector.
• Steam Jet Ejector is used to raise the temperature and pressure of
generated vapors from first effect of evaporator
• Motive steam mixes with the part of vapors generated from evaporator.
• It increase overall energy efficiency of
Multiple effect Evaporation Plant.
Mechanical Vapor Recompression
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Evaporator
Vapor out
Vapor to evap
Feed
Concentrated
product
Condensate out
Electrical motor
MVR
Excess vapor to
condenser
Agitated Thin Film Dryer (ATFD)
Agitated Thin Film Dryer (ATFD)
ATFD consists of two major assemblies:
• A Heated body (Shell with surrounding Jacket)
• A close clearance or zero clearance rotor with blades.
During ATFD Operation 3 zones are formed:
• Preheating zone - Product reaches to boiling point.
• Slurry zone - Concentration of solids increases. Many
products during this phase tend to form agglomerates which
are crushed by the pendulum blades.
• Powder Zone – Dry powder (90% w/w solids)
© Praj Industries Ltd www.praj.net 30
Use for amorphous salts which can not be separated in Pusher Centrifuge
How ATFD Works ?
• Fluid enters tangentially above the heated zone
• Feed Distribution by using distribution ring
mounted on rotor
• Blades helps in spreading fluid over the entire
heated wall and forms a thin film.
• Turbulent condition developed by the rotor blades
generates optimal heat flux and hence rapid
evaporation
• Evaporated vapors are condensed in a surface
condenser
© Praj Industries Ltd www.praj.net 31
Product Powder from ATFD
© Praj Industries Ltd www.praj.net
ATFD ROTOR BALANCING
ATFD UNDER OPERATION (20 m2)
Successful Installations
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
3 Effect TVR Based MEE. .
• Effluent is having 22% w/w
NaCl
• Concentrating up to 40% w/w
• Recovering 55 MT /day NaCl
Recovery
TVR Based MEE. .
• ZLD system for Textile
Industry
Flubex Installation. . .
• Organic Rich Effluent
• Highly viscose at higher coc.
• Concentrating from initial 12 %
w/w to 55% w/w
• Final product fired in boiler for
steam generation
WTP Installation. . .• WTP for Food & Beverages Plant
• De-alkalized & UF treated water for
Carbonated Soft Drink
• Steam sanitization and in-situ hot CIP to
meet stringent water norms for food grade
application
• Treatment to ensure pesticide free water
WTP Installation. . .
• WTP for Pharma to meet water for injection
quality
• 2 x 25 m3/hr UF + RO
Biological ETP Installation. . .
Conventional Aerobic
SBR Based Aerobic
UASB Based Anaerobic
CSTR Based Anaerobic
MBR Based Anaerobic Membrane Tank
Solvent Recovery
Type of Solvents
© Praj Industries Ltd www.praj.net 44
• Aqueous non-azeotropic: Miscible with water and forming
no azotrop
• Other non-azeotropic: Miscible with each other and
forming no azotrop
• Heterogeneous azeotropic : Not Miscible with each other
and forming azotrop
• Aqueous azeotropic: Miscible with water and forming
azotrop
• Homogeneous azeotropic : Miscible with each other
forming Azeotrop
Separation Techniques
© Praj Industries Ltd www.praj.net 45
Pressure swing distillation:
Altering volatility by taking advantage of solvent properties at variable
pressures
Azeotropic distillation:
Addition of additional agent called entrainer which alter the volatility
of one of the solvent
Chemical action separation:
Addition of chemical which is having affinity for one of the
constituent.
Distillation using a dissolved salt:
Salts are added to increase the boiling point elevation of solvent
and decrease the volatality of solvent in which it is dissolved.
Solvent Stripper System• EXPECTED SOLVENTS IN EFFLUENT FROM PHARMA INDUSTRIES
© Praj Industries Ltd
www.praj.net 46
Solvent Boiling Point (ºC)
Acetic Acid 118.0
Acetic Acid Anhydride 139.0
Acetone 56.3
Acetonitrile 81.6
Benzene 80.1
iso-Butanol 107.7
n-Butanol 117.7
tert-Butanol 82.5
Carbon Tetrachloride 76.5
Chlorobenzene 131.7
Chloroform 61.2
Cyclohexane 80.7
Cyclopentane 49.3
Dichloromethane 39.8
Diethyl Ether 34.6
Dimethyl Acetamide 166.1
Dimethyl Formamide 153.0
Dimethyl Sulfoxide 189.0
Dioxane 101.0
Solvent Boiling Point (ºC)
Ethyl Ether 34.6
Ethylene Dichloride 83.5
Ethylene Glycol 197.5
Heptane 98.4
n-Hexane 68.7
Hydrochloric Acid 84.8
Methanol 64.7
Methylene Chloride 39.8
MTBE 55.2
Pentane 36.1
Petroleum Ether 35.0-60.0
iso-Propanol 82.3
n-Propanol 97.2
Pyridine 115.3
Tetrahydrofuran 66.0
Toluene 110.6
Trifluoroacetic Acid 71.8
Water 100.0
Xylene 140.0
Kundali of Solvents
© Praj Industries Ltd www.praj.net 47
Composition of
Solvents
Product
Quality
Final Product
Specifications
Capital
Cost
Regulatory Pressure
Cost of
Labor
Material of
Construction
Value Added Co
product
Site Climatic
Conditions
Cost of Energy
Discussions
Manish Kharwade
manishkharwade@praj.net
© Praj Industries Ltd www.praj.net
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