Industrial wastewater treatment
Encyclopedia
Industrial wastewater treatment covers the mechanisms and processes used to treat waters that have been contaminated in some way by anthropogenic industrial or commercial activities prior to its release into the environment or its re-use.
Most industries produce some wet waste although recent trends in the developed world have been to minimise such production or recycle such waste within the production process. However, many industries remain dependent on processes that produce wastewater
s.
from its ores involves powerful reduction
reactions in blast furnaces. Cooling waters are inevitably contaminated with products especially ammonia
and cyanide
. Production of coke from coal in coking plants also requires water cooling and the use of water in by-products separation. Contamination of waste streams includes gasification products such as benzene
, naphthalene
, anthracene
, cyanide, ammonia, phenol
s, cresol
s together with a range of more complex organic compounds known collectively as polycyclic aromatic hydrocarbon
s (PAH).
The conversion of iron or steel into sheet, wire or rods requires hot and cold mechanical transformation stages frequently employing water as a lubricant and coolant. Contaminants include hydraulic oils, tallow
and particulate solids.
Final treatment of iron and steel products before onward sale into manufacturing includes pickling in strong mineral acid to remove rust and prepare the surface for tin
or chromium
plating or for other surface treatments such as galvanisation or paint
ing. The two acids commonly used are hydrochloric acid
and sulfuric acid
. Wastewaters include acidic rinse waters together with waste acid. Although many plants operate acid recovery plants, (particularly those using Hydrochloric acid), where the mineral acid is boiled away from the iron salts, there remains a large volume of highly acid ferrous sulfate
or ferrous chloride to be disposed of. Many steel industry wastewater
s are contaminated by hydraulic oil also known as soluble oil.
s and quarries
are slurries of rock particles in water. These arise from rainfall washing exposed surfaces and haul roads and also from rock washing and grading processes. Volumes of water can be very high, especially rainfall related arisings on large sites. Some specialized separation operations, such as coal
washing
to separate coal from native rock using density gradients
, can produce wastewater contaminated by fine particulate haematite and surfactants. Oil
s and hydraulic oils are also common contaminants.
Wastewater from metal mines and ore recovery plants are inevitably contaminated by the minerals present in the native rock formations. Following crushing and extraction of the desirable materials, undesirable materials may become contaminated in the wastewater. For metal mines, this can include unwanted metals such as zinc
and other materials such as arsenic
. Extraction of high value metals such as gold
and silver
may generate slimes containing very fine particles in where physical removal of contaminants becomes particularly difficult.
plants throughout the world: it is biodegradable and nontoxic, but that has high concentrations of biochemical oxygen demand
(BOD) and suspended solids
(SS). The constituents of food and agriculture wastewater are often complex to predict due to the differences in BOD and pH
in effluents from vegetable, fruit, and meat products and due to the seasonal nature of food processing and postharvesting.
Processing of food from raw materials requires large volumes of high grade water. Vegetable washing generates waters with high loads of particulate matter and some dissolved organics
. It may also contain surfactants.
Animal slaughter and processing produces very strong organic waste from body fluids, such as blood
, and gut
contents. This wastewater is frequently contaminated by significant levels of antibiotic
s and growth hormone
s from the animals and by a variety of pesticides used to control external parasites. Insecticide residues in fleeces is a particular problem in treating waters generated in wool
processing.
Processing food for sale produces wastes generated from cooking which are often rich in plant organic material and may also contain salt
, flavourings, colouring material and acid
s or alkali
. Very significant quantities of oil or fats may also be present.
s, pharmaceuticals, paints and dye
s, petro-chemicals, detergent
s, plastic
s, paper pollution
, etc. Waste waters can be contaminated by feed-stock materials, by-products, product material in soluble or particulate form, washing and cleaning agents, solvents and added value products such as plasticisers. Treatment facilities that do not need control of their effluent typically opt for a type of aerobic treatment, i.e. Aerated Lagoons
.
.
.) Many industries have a need to treat water to obtain very high quality water for demanding purposes. Water treatment produces organic and mineral sludges from filtration
and sedimentation
. Ion exchange
using natural or synthetic resins removes calcium
, magnesium
and carbonate
ions from water, replacing them with hydrogen
and hydroxyl
ions. Regeneration of ion exchange columns with strong acids and alkalis produces a wastewater rich in hardness ions which are readily precipitated out, especially when in admixture with other wastewaters.
or sludge. Very fine solids and solids with densities close to the density of water pose special problems. In such case filtration or ultrafiltration
may be required. Although, flocculation
may be used, using alum
salts or the addition of polyelectrolyte
s.
Many oils can be recovered from open water surfaces by skimming devices. Considered a dependable and cheap way to remove oil, grease and other hydrocarbons from water, oil skimmers can sometimes achieve the desired level of water purity. At other times, skimming is also a cost-efficient method to remove most of the oil before using membrane filters and chemical processes. Skimmers will prevent filters from blinding prematurely and keep chemical costs down because there is less oil to process.
Because grease skimming involves higher viscosity hydrocarbons, skimmers must be equipped with heaters powerful enough to keep grease fluid for discharge. If floating grease forms into solid clumps or mats, a spray bar, aerator or mechanical apparatus can be used to facilitate removal.
However, hydraulic oils and the majority of oils that have degraded to any extent will also have a soluble or emulsified component that will require further treatment to eliminate. Dissolving or emulsifying oil using surfactants or solvent
s usually exacerbates the problem rather than solving it, producing wastewater that is more difficult to treat.
The wastewaters from large-scale industries such as oil refineries
, petrochemical plants
, chemical plant
s, and natural gas processing plant
s commonly contain gross amounts of oil and suspended solids. Those industries use a device known as an API oil-water separator
which is designed to separate the oil and suspended solids from their wastewater effluents. The name is derived from the fact that such separators are designed according to standards published by the American Petroleum Institute
(API).
The API separator is a gravity separation device designed by using Stokes Law
to define the rise velocity of oil droplets based on their density
and size. The design is based on the specific gravity
difference between the oil and the wastewater because that difference is much smaller than the specific gravity difference between the suspended solids and water. The suspended solids settles to the bottom of the separator as a sediment layer, the oil rises to top of the separator and the cleansed wastewater is the middle layer between the oil layer and the solids.
Typically, the oil layer is skimmed off and subsequently re-processed or disposed of, and the bottom sediment layer is removed by a chain and flight scraper (or similar device) and a sludge pump. The water layer is sent to further treatment consisting usually of a Electroflotation module for additional removal of any residual oil and then to some type of biological treatment unit for removal of undesirable dissolved chemical compounds.
Parallel plate separators are similar to API separators but they include tilted parallel plate assemblies (also known as parallel packs). The parallel plates provide more surface for suspended oil droplets to coalesce into larger globules. Such separators still depend upon the specific gravity between the suspended oil and the water. However, the parallel plates enhance the degree of oil-water separation. The result is that a parallel plate separator requires significantly less space than a conventional API separator to achieve the same degree of separation.
processes such as activated sludge
or trickling filter
. Problems can arise if the wastewater is excessively diluted with washing water or is highly concentrated such as neat blood or milk. The presence of cleaning agents, disinfectants, pesticides, or antibiotics can have detrimental impacts on treatment processes.
Activated sludge is a biochemical process for treating sewage and industrial wastewater that uses air (or oxygen
) and microorganism
s to biologically oxidize organic pollutants, producing a waste sludge (or floc
) containing the oxidized material. In general, an activated sludge process includes:
1. ASP : Activated Sludge process
2. SAFF system of Submerged aerobic fixed film system
3. MBBR : Moving bed bio reactor ( Anox invented this now is considered generic technology)
4. MBR : Membrane Bioreactor
5. DAF clarifiers
6. TBR : Turbo bioreactor Technology ( A patented technology of Wockoliver)
7. Filtration technologies
More information about above can be found on various commercial manufactures like WOIL
A trickling filter consists of a bed of rocks
, gravel
, slag
, peat moss, or plastic media over which wastewater flows downward and contacts a layer (or film) of microbial slime covering the bed media. Aerobic conditions are maintained by forced air flowing through the bed or by natural convection of air. The process involves adsorption
of organic compounds in the wastewater by the microbial slime layer, diffusion of air into the slime layer to provide the oxygen
required for the biochemical oxidation of the organic compounds. The end products include carbon dioxide
gas, water and other products of the oxidation. As the slime layer thickens, it becomes difficult for the air to penetrate the layer and an inner anaerobic layer is formed.
The components of a complete trickling filter system are: fundamental components:
The treatment of sewage or other wastewater with trickling filters is among the oldest and most well characterized treatment technologies.
A trickling filter is also often called a trickle filter, trickling biofilter, biofilter
, biological filter or biological trickling filter.
ing, distillation
, adsorption, vitrification
, incineration
, chemical immobilisation or landfill disposal. Some materials such as some detergents may be capable of biological degradation and in such cases, a modified form of wastewater treatment can be used.
that will require treatment as a solid residue that may also be toxic. In some cases, gasses may be evolved requiring treatment for the gas stream. Some other forms of treatment are usually required following neutralisation.
Waste streams rich in hardness
ions as from de-ionisation processes can readily lose the hardness ions in a buildup of precipitated calcium and magnesium salts. This precipitation process can cause severe furring of pipes and can, in extreme cases, cause the blockage of disposal pipes. A 1 metre diameter industrial marine discharge pipe serving a major chemicals complex was blocked by such salts in the 1970s. Treatment is by concentration of de-ionisation waste waters and disposal to landfill or by careful pH management of the released wastewater.
, thallium
, etc.) acids, alkalis, non-metallic elements (such as arsenic or selenium
) are generally resistant to biological processes unless very dilute. Metals can often be precipitated out by changing the pH or by treatment with other chemicals. Many, however, are resistant to treatment or mitigation and may require concentration followed by landfilling or recycling. Dissolved organics can be incinerated within the wastewater by Advanced Oxidation Process
.
Most industries produce some wet waste although recent trends in the developed world have been to minimise such production or recycle such waste within the production process. However, many industries remain dependent on processes that produce wastewater
Wastewater
Wastewater is any water that has been adversely affected in quality by anthropogenic influence. It comprises liquid waste discharged by domestic residences, commercial properties, industry, and/or agriculture and can encompass a wide range of potential contaminants and concentrations...
s.
Iron and steel industry
The production of ironIron
Iron is a chemical element with the symbol Fe and atomic number 26. It is a metal in the first transition series. It is the most common element forming the planet Earth as a whole, forming much of Earth's outer and inner core. It is the fourth most common element in the Earth's crust...
from its ores involves powerful reduction
Redox
Redox reactions describe all chemical reactions in which atoms have their oxidation state changed....
reactions in blast furnaces. Cooling waters are inevitably contaminated with products especially ammonia
Ammonia
Ammonia is a compound of nitrogen and hydrogen with the formula . It is a colourless gas with a characteristic pungent odour. Ammonia contributes significantly to the nutritional needs of terrestrial organisms by serving as a precursor to food and fertilizers. Ammonia, either directly or...
and cyanide
Cyanide
A cyanide is a chemical compound that contains the cyano group, -C≡N, which consists of a carbon atom triple-bonded to a nitrogen atom. Cyanides most commonly refer to salts of the anion CN−. Most cyanides are highly toxic....
. Production of coke from coal in coking plants also requires water cooling and the use of water in by-products separation. Contamination of waste streams includes gasification products such as benzene
Benzene
Benzene is an organic chemical compound. It is composed of 6 carbon atoms in a ring, with 1 hydrogen atom attached to each carbon atom, with the molecular formula C6H6....
, naphthalene
Naphthalene
Naphthalene is an organic compound with formula . It is a white crystalline solid with a characteristic odor that is detectable at concentrations as low as 0.08 ppm by mass. As an aromatic hydrocarbon, naphthalene's structure consists of a fused pair of benzene rings...
, anthracene
Anthracene
Anthracene is a solid polycyclic aromatic hydrocarbon consisting of three fused benzene rings. It is a component of coal-tar. Anthracene is used in the production of the red dye alizarin and other dyes...
, cyanide, ammonia, phenol
Phenol
Phenol, also known as carbolic acid, phenic acid, is an organic compound with the chemical formula C6H5OH. It is a white crystalline solid. The molecule consists of a phenyl , bonded to a hydroxyl group. It is produced on a large scale as a precursor to many materials and useful compounds...
s, cresol
Cresol
Cresols are organic compounds which are methylphenols. They are a widely occurring natural and manufactured group of aromatic organic compounds which are categorized as phenols . Depending on the temperature, cresols can be solid or liquid because they have melting points not far from room...
s together with a range of more complex organic compounds known collectively as polycyclic aromatic hydrocarbon
Polycyclic aromatic hydrocarbon
Polycyclic aromatic hydrocarbons , also known as poly-aromatic hydrocarbons or polynuclear aromatic hydrocarbons, are potent atmospheric pollutants that consist of fused aromatic rings and do not contain heteroatoms or carry substituents. Naphthalene is the simplest example of a PAH...
s (PAH).
The conversion of iron or steel into sheet, wire or rods requires hot and cold mechanical transformation stages frequently employing water as a lubricant and coolant. Contaminants include hydraulic oils, tallow
Tallow
Tallow is a rendered form of beef or mutton fat, processed from suet. It is solid at room temperature. Unlike suet, tallow can be stored for extended periods without the need for refrigeration to prevent decomposition, provided it is kept in an airtight container to prevent oxidation.In industry,...
and particulate solids.
Final treatment of iron and steel products before onward sale into manufacturing includes pickling in strong mineral acid to remove rust and prepare the surface for tin
Tin
Tin is a chemical element with the symbol Sn and atomic number 50. It is a main group metal in group 14 of the periodic table. Tin shows chemical similarity to both neighboring group 14 elements, germanium and lead and has two possible oxidation states, +2 and the slightly more stable +4...
or chromium
Chromium
Chromium is a chemical element which has the symbol Cr and atomic number 24. It is the first element in Group 6. It is a steely-gray, lustrous, hard metal that takes a high polish and has a high melting point. It is also odorless, tasteless, and malleable...
plating or for other surface treatments such as galvanisation or paint
Paint
Paint is any liquid, liquefiable, or mastic composition which after application to a substrate in a thin layer is converted to an opaque solid film. One may also consider the digital mimicry thereof...
ing. The two acids commonly used are hydrochloric acid
Hydrochloric acid
Hydrochloric acid is a solution of hydrogen chloride in water, that is a highly corrosive, strong mineral acid with many industrial uses. It is found naturally in gastric acid....
and sulfuric acid
Sulfuric acid
Sulfuric acid is a strong mineral acid with the molecular formula . Its historical name is oil of vitriol. Pure sulfuric acid is a highly corrosive, colorless, viscous liquid. The salts of sulfuric acid are called sulfates...
. Wastewaters include acidic rinse waters together with waste acid. Although many plants operate acid recovery plants, (particularly those using Hydrochloric acid), where the mineral acid is boiled away from the iron salts, there remains a large volume of highly acid ferrous sulfate
Iron(II) sulfate
Iron sulfate or ferrous sulfate is the chemical compound with the formula FeSO4. Known since ancient times as copperas and as green vitriol, the blue-green heptahydrate is the most common form of this material...
or ferrous chloride to be disposed of. Many steel industry wastewater
Wastewater
Wastewater is any water that has been adversely affected in quality by anthropogenic influence. It comprises liquid waste discharged by domestic residences, commercial properties, industry, and/or agriculture and can encompass a wide range of potential contaminants and concentrations...
s are contaminated by hydraulic oil also known as soluble oil.
Mines and quarries
The principal waste-waters associated with mineMining
Mining is the extraction of valuable minerals or other geological materials from the earth, from an ore body, vein or seam. The term also includes the removal of soil. Materials recovered by mining include base metals, precious metals, iron, uranium, coal, diamonds, limestone, oil shale, rock...
s and quarries
Quarry
A quarry is a type of open-pit mine from which rock or minerals are extracted. Quarries are generally used for extracting building materials, such as dimension stone, construction aggregate, riprap, sand, and gravel. They are often collocated with concrete and asphalt plants due to the requirement...
are slurries of rock particles in water. These arise from rainfall washing exposed surfaces and haul roads and also from rock washing and grading processes. Volumes of water can be very high, especially rainfall related arisings on large sites. Some specialized separation operations, such as coal
Coal
Coal is a combustible black or brownish-black sedimentary rock usually occurring in rock strata in layers or veins called coal beds or coal seams. The harder forms, such as anthracite coal, can be regarded as metamorphic rock because of later exposure to elevated temperature and pressure...
washing
Washing
Washing is one way of cleaning, namely with water and often some kind of soap or detergent. Washing is an essential part of good hygiene and health....
to separate coal from native rock using density gradients
Density Gradient
Density gradient is a spatial variation in density over an area. The term is used in the natural sciences to describe varying density of matter, but can apply to any quantity whose density can be measured...
, can produce wastewater contaminated by fine particulate haematite and surfactants. Oil
Oil
An oil is any substance that is liquid at ambient temperatures and does not mix with water but may mix with other oils and organic solvents. This general definition includes vegetable oils, volatile essential oils, petrochemical oils, and synthetic oils....
s and hydraulic oils are also common contaminants.
Wastewater from metal mines and ore recovery plants are inevitably contaminated by the minerals present in the native rock formations. Following crushing and extraction of the desirable materials, undesirable materials may become contaminated in the wastewater. For metal mines, this can include unwanted metals such as zinc
Zinc
Zinc , or spelter , is a metallic chemical element; it has the symbol Zn and atomic number 30. It is the first element in group 12 of the periodic table. Zinc is, in some respects, chemically similar to magnesium, because its ion is of similar size and its only common oxidation state is +2...
and other materials such as arsenic
Arsenic
Arsenic is a chemical element with the symbol As, atomic number 33 and relative atomic mass 74.92. Arsenic occurs in many minerals, usually in conjunction with sulfur and metals, and also as a pure elemental crystal. It was first documented by Albertus Magnus in 1250.Arsenic is a metalloid...
. Extraction of high value metals such as gold
Gold
Gold is a chemical element with the symbol Au and an atomic number of 79. Gold is a dense, soft, shiny, malleable and ductile metal. Pure gold has a bright yellow color and luster traditionally considered attractive, which it maintains without oxidizing in air or water. Chemically, gold is a...
and silver
Silver
Silver is a metallic chemical element with the chemical symbol Ag and atomic number 47. A soft, white, lustrous transition metal, it has the highest electrical conductivity of any element and the highest thermal conductivity of any metal...
may generate slimes containing very fine particles in where physical removal of contaminants becomes particularly difficult.
Food industry
Wastewater generated from agricultural and food operations has distinctive characteristics that set it apart from common municipal wastewater managed by public or private wastewater treatmentSewage treatment
Sewage treatment, or domestic wastewater treatment, is the process of removing contaminants from wastewater and household sewage, both runoff and domestic. It includes physical, chemical, and biological processes to remove physical, chemical and biological contaminants...
plants throughout the world: it is biodegradable and nontoxic, but that has high concentrations of biochemical oxygen demand
Biochemical oxygen demand
Biochemical oxygen demand or B.O.D. is the amount of dissolved oxygen needed by aerobic biological organisms in a body of water to break down organic material present in a given water sample at certain temperature over a specific time period. The term also refers to a chemical procedure for...
(BOD) and suspended solids
Total suspended solids
Total suspended solids is a water quality measurement usually abbreviated TSS. It is listed as a conventional pollutant in the U.S. Clean Water Act. This parameter was at one time called non-filterable residue , a term that refers to the identical measurement: the dry-weight of particles trapped...
(SS). The constituents of food and agriculture wastewater are often complex to predict due to the differences in BOD and pH
PH
In chemistry, pH is a measure of the acidity or basicity of an aqueous solution. Pure water is said to be neutral, with a pH close to 7.0 at . Solutions with a pH less than 7 are said to be acidic and solutions with a pH greater than 7 are basic or alkaline...
in effluents from vegetable, fruit, and meat products and due to the seasonal nature of food processing and postharvesting.
Processing of food from raw materials requires large volumes of high grade water. Vegetable washing generates waters with high loads of particulate matter and some dissolved organics
Organic matter
Organic matter is matter that has come from a once-living organism; is capable of decay, or the product of decay; or is composed of organic compounds...
. It may also contain surfactants.
Animal slaughter and processing produces very strong organic waste from body fluids, such as blood
Blood
Blood is a specialized bodily fluid in animals that delivers necessary substances such as nutrients and oxygen to the cells and transports metabolic waste products away from those same cells....
, and gut
Gut (zoology)
In zoology, the gut, also known as the alimentary canal or alimentary tract, is a tube by which bilaterian animals transfer food to the digestion organs. In large bilaterians the gut generally also has an exit, the anus, by which the animal disposes of solid wastes...
contents. This wastewater is frequently contaminated by significant levels of antibiotic
Antibiotic
An antibacterial is a compound or substance that kills or slows down the growth of bacteria.The term is often used synonymously with the term antibiotic; today, however, with increased knowledge of the causative agents of various infectious diseases, antibiotic has come to denote a broader range of...
s and growth hormone
Hormone
A hormone is a chemical released by a cell or a gland in one part of the body that sends out messages that affect cells in other parts of the organism. Only a small amount of hormone is required to alter cell metabolism. In essence, it is a chemical messenger that transports a signal from one...
s from the animals and by a variety of pesticides used to control external parasites. Insecticide residues in fleeces is a particular problem in treating waters generated in wool
Wool
Wool is the textile fiber obtained from sheep and certain other animals, including cashmere from goats, mohair from goats, qiviut from muskoxen, vicuña, alpaca, camel from animals in the camel family, and angora from rabbits....
processing.
Processing food for sale produces wastes generated from cooking which are often rich in plant organic material and may also contain salt
Salt
In chemistry, salts are ionic compounds that result from the neutralization reaction of an acid and a base. They are composed of cations and anions so that the product is electrically neutral...
, flavourings, colouring material and acid
Acid
An acid is a substance which reacts with a base. Commonly, acids can be identified as tasting sour, reacting with metals such as calcium, and bases like sodium carbonate. Aqueous acids have a pH of less than 7, where an acid of lower pH is typically stronger, and turn blue litmus paper red...
s or alkali
Alkali
In chemistry, an alkali is a basic, ionic salt of an alkali metal or alkaline earth metal element. Some authors also define an alkali as a base that dissolves in water. A solution of a soluble base has a pH greater than 7. The adjective alkaline is commonly used in English as a synonym for base,...
. Very significant quantities of oil or fats may also be present.
Complex organic chemicals industry
A range of industries manufacture or use complex organic chemicals. These include pesticidePesticide
Pesticides are substances or mixture of substances intended for preventing, destroying, repelling or mitigating any pest.A pesticide may be a chemical unicycle, biological agent , antimicrobial, disinfectant or device used against any pest...
s, pharmaceuticals, paints and dye
Dye
A dye is a colored substance that has an affinity to the substrate to which it is being applied. The dye is generally applied in an aqueous solution, and requires a mordant to improve the fastness of the dye on the fiber....
s, petro-chemicals, detergent
Detergent
A detergent is a surfactant or a mixture of surfactants with "cleaning properties in dilute solutions." In common usage, "detergent" refers to alkylbenzenesulfonates, a family of compounds that are similar to soap but are less affected by hard water...
s, plastic
Plastic
A plastic material is any of a wide range of synthetic or semi-synthetic organic solids used in the manufacture of industrial products. Plastics are typically polymers of high molecular mass, and may contain other substances to improve performance and/or reduce production costs...
s, paper pollution
Paper pollution
The production and use of paper has a number of adverse effects on the environment which are known collectively as paper pollution. Pulp mills contribute to air, water and land pollution. Discarded paper is a major component of many landfill sites, accounting for about 35 percent by weight of...
, etc. Waste waters can be contaminated by feed-stock materials, by-products, product material in soluble or particulate form, washing and cleaning agents, solvents and added value products such as plasticisers. Treatment facilities that do not need control of their effluent typically opt for a type of aerobic treatment, i.e. Aerated Lagoons
Aerated lagoon
An aerated lagoon or aerated basin is a holding and/or treatment pond provided with artificial aeration to promote the biological oxidation of wastewaters. There are many other biological processes for treatment of wastewaters, for example activated sludge, trickling filters, rotating biological...
.
Nuclear industry
The waste production from the nuclear and radio-chemicals industry is dealt with as Radioactive wasteRadioactive waste
Radioactive wastes are wastes that contain radioactive material. Radioactive wastes are usually by-products of nuclear power generation and other applications of nuclear fission or nuclear technology, such as research and medicine...
.
Water treatment
Water treatment for the production of drinking water is dealt with elsewhere. (See water purificationWater purification
Water purification is the process of removing undesirable chemicals, materials, and biological contaminants from contaminated water. The goal is to produce water fit for a specific purpose...
.) Many industries have a need to treat water to obtain very high quality water for demanding purposes. Water treatment produces organic and mineral sludges from filtration
Filtration
Filtration is commonly the mechanical or physical operation which is used for the separation of solids from fluids by interposing a medium through which only the fluid can pass...
and sedimentation
Sedimentation (water treatment)
Sedimentation is a physical water treatment process used to settle out suspended solids in water under the influence of gravity.-Basics:Suspended solids , is the mass of dry solids retained by a filter of a given porosity related to the volume of the water sample...
. Ion exchange
Ion exchange
Ion exchange is an exchange of ions between two electrolytes or between an electrolyte solution and a complex. In most cases the term is used to denote the processes of purification, separation, and decontamination of aqueous and other ion-containing solutions with solid polymeric or mineralic 'ion...
using natural or synthetic resins removes calcium
Calcium
Calcium is the chemical element with the symbol Ca and atomic number 20. It has an atomic mass of 40.078 amu. Calcium is a soft gray alkaline earth metal, and is the fifth-most-abundant element by mass in the Earth's crust...
, magnesium
Magnesium
Magnesium is a chemical element with the symbol Mg, atomic number 12, and common oxidation number +2. It is an alkaline earth metal and the eighth most abundant element in the Earth's crust and ninth in the known universe as a whole...
and carbonate
Carbonate
In chemistry, a carbonate is a salt of carbonic acid, characterized by the presence of the carbonate ion, . The name may also mean an ester of carbonic acid, an organic compound containing the carbonate group C2....
ions from water, replacing them with hydrogen
Hydrogen
Hydrogen is the chemical element with atomic number 1. It is represented by the symbol H. With an average atomic weight of , hydrogen is the lightest and most abundant chemical element, constituting roughly 75% of the Universe's chemical elemental mass. Stars in the main sequence are mainly...
and hydroxyl
Hydroxyl
A hydroxyl is a chemical group containing an oxygen atom covalently bonded with a hydrogen atom. In inorganic chemistry, the hydroxyl group is known as the hydroxide ion, and scientists and reference works generally use these different terms though they refer to the same chemical structure in...
ions. Regeneration of ion exchange columns with strong acids and alkalis produces a wastewater rich in hardness ions which are readily precipitated out, especially when in admixture with other wastewaters.
Treatment of industrial wastewater
The different types of contamination of wastewater require a variety of strategies to remove the contamination.Solids removal
Most solids can be removed using simple sedimentation techniques with the solids recovered as slurrySlurry
A slurry is, in general, a thick suspension of solids in a liquid.-Examples of slurries:Examples of slurries include:* Lahars* A mixture of water and cement to form concrete* A mixture of water, gelling agent, and oxidizers used as an explosive...
or sludge. Very fine solids and solids with densities close to the density of water pose special problems. In such case filtration or ultrafiltration
Ultrafiltration (industrial)
Ultrafiltration is a type of membrane technical filtration. Industries such as chemical and pharmaceutical manufacturing, food and beverage processing, and waste water treatment, employ ultrafiltration in order to recycle flow or add value to later products...
may be required. Although, flocculation
Flocculation
Flocculation, in the field of chemistry, is a process wherein colloids come out of suspension in the form of floc or flakes by the addition of a clarifying agent. The action differs from precipitation in that, prior to flocculation, colloids are merely suspended in a liquid and not actually...
may be used, using alum
Alum
Alum is both a specific chemical compound and a class of chemical compounds. The specific compound is the hydrated potassium aluminium sulfate with the formula KAl2.12H2O. The wider class of compounds known as alums have the related empirical formula, AB2.12H2O.-Chemical properties:Alums are...
salts or the addition of polyelectrolyte
Polyelectrolyte
Polyelectrolytes are polymers whose repeating units bear an electrolyte group. These groups will dissociate in aqueous solutions , making the polymers charged. Polyelectrolyte properties are thus similar to both electrolytes and polymers , and are sometimes called polysalts. Like salts, their...
s.
Oils and grease removal
Because grease skimming involves higher viscosity hydrocarbons, skimmers must be equipped with heaters powerful enough to keep grease fluid for discharge. If floating grease forms into solid clumps or mats, a spray bar, aerator or mechanical apparatus can be used to facilitate removal.
However, hydraulic oils and the majority of oils that have degraded to any extent will also have a soluble or emulsified component that will require further treatment to eliminate. Dissolving or emulsifying oil using surfactants or solvent
Solvent
A solvent is a liquid, solid, or gas that dissolves another solid, liquid, or gaseous solute, resulting in a solution that is soluble in a certain volume of solvent at a specified temperature...
s usually exacerbates the problem rather than solving it, producing wastewater that is more difficult to treat.
The wastewaters from large-scale industries such as oil refineries
Oil refinery
An oil refinery or petroleum refinery is an industrial process plant where crude oil is processed and refined into more useful petroleum products, such as gasoline, diesel fuel, asphalt base, heating oil, kerosene, and liquefied petroleum gas...
, petrochemical plants
Petrochemical
Petrochemicals are chemical products derived from petroleum. Some chemical compounds made from petroleum are also obtained from other fossil fuels, such as coal or natural gas, or renewable sources such as corn or sugar cane....
, chemical plant
Chemical plant
A chemical plant is an industrial process plant that manufactures chemicals, usually on a large scale. The general objective of a chemical plant is to create new material wealth via the chemical or biological transformation and or separation of materials. Chemical plants use special equipment,...
s, and natural gas processing plant
Natural gas processing
Natural-gas processing is a complex industrial process designed to clean raw natural gas by separating impurities and various non-methane hydrocarbons and fluids to produce what is known as pipeline quality dry natural gas.-Background:...
s commonly contain gross amounts of oil and suspended solids. Those industries use a device known as an API oil-water separator
API oil-water separator
An API oil-water separator is a device designed to separate gross amounts of oil and suspended solids from the wastewater effluents of oil refineries, petrochemical plants, chemical plants, natural gas processing plants and other industrial sources...
which is designed to separate the oil and suspended solids from their wastewater effluents. The name is derived from the fact that such separators are designed according to standards published by the American Petroleum Institute
American Petroleum Institute
The American Petroleum Institute, commonly referred to as API, is the largest U.S trade association for the oil and natural gas industry...
(API).
The API separator is a gravity separation device designed by using Stokes Law
Stokes law
Stokes' law can refer to:*Stokes' law for friction force*Stokes' law law describing attenuation of sound in Newtonian liquidsFor integration, see Stokes' theorem....
to define the rise velocity of oil droplets based on their density
Density
The mass density or density of a material is defined as its mass per unit volume. The symbol most often used for density is ρ . In some cases , density is also defined as its weight per unit volume; although, this quantity is more properly called specific weight...
and size. The design is based on the specific gravity
Specific gravity
Specific gravity is the ratio of the density of a substance to the density of a reference substance. Apparent specific gravity is the ratio of the weight of a volume of the substance to the weight of an equal volume of the reference substance. The reference substance is nearly always water for...
difference between the oil and the wastewater because that difference is much smaller than the specific gravity difference between the suspended solids and water. The suspended solids settles to the bottom of the separator as a sediment layer, the oil rises to top of the separator and the cleansed wastewater is the middle layer between the oil layer and the solids.
Typically, the oil layer is skimmed off and subsequently re-processed or disposed of, and the bottom sediment layer is removed by a chain and flight scraper (or similar device) and a sludge pump. The water layer is sent to further treatment consisting usually of a Electroflotation module for additional removal of any residual oil and then to some type of biological treatment unit for removal of undesirable dissolved chemical compounds.
Removal of biodegradable organics
Biodegradable organic material of plant or animal origin is usually possible to treat using extended conventional wastewater treatmentWastewater Treatment
Wastewater treatment may refer to:* Sewage treatment* Industrial wastewater treatment...
processes such as activated sludge
Activated sludge
Activated sludge is a process for treating sewage and industrial wastewaters using air and a biological floc composed of bacteria and protozoans.-Purpose:...
or trickling filter
Trickling filter
A trickling filter consists of a fixed bed of rocks, lava, coke, gravel, slag, polyurethane foam, sphagnum peat moss, ceramic, or plastic media over which sewage or other wastewater flows downward and causes a layer of microbial slime to grow, covering the bed of media...
. Problems can arise if the wastewater is excessively diluted with washing water or is highly concentrated such as neat blood or milk. The presence of cleaning agents, disinfectants, pesticides, or antibiotics can have detrimental impacts on treatment processes.
Activated sludge process
Oxygen
Oxygen is the element with atomic number 8 and represented by the symbol O. Its name derives from the Greek roots ὀξύς and -γενής , because at the time of naming, it was mistakenly thought that all acids required oxygen in their composition...
) and microorganism
Microorganism
A microorganism or microbe is a microscopic organism that comprises either a single cell , cell clusters, or no cell at all...
s to biologically oxidize organic pollutants, producing a waste sludge (or floc
Flocculation
Flocculation, in the field of chemistry, is a process wherein colloids come out of suspension in the form of floc or flakes by the addition of a clarifying agent. The action differs from precipitation in that, prior to flocculation, colloids are merely suspended in a liquid and not actually...
) containing the oxidized material. In general, an activated sludge process includes:
- An aeration tank where air (or oxygen) is injected and thoroughly mixed into the wastewater.
- A settling tank (usually referred to as a "clarifier" or "settler") to allow the waste sludge to settle. Part of the waste sludge is recycled to the aeration tank and the remaining waste sludge is removed for further treatment and ultimate disposal.
- As a general process for most of the Industrial waste water the following Technologies are used.
1. ASP : Activated Sludge process
2. SAFF system of Submerged aerobic fixed film system
3. MBBR : Moving bed bio reactor ( Anox invented this now is considered generic technology)
4. MBR : Membrane Bioreactor
5. DAF clarifiers
6. TBR : Turbo bioreactor Technology ( A patented technology of Wockoliver)
7. Filtration technologies
More information about above can be found on various commercial manufactures like WOIL
Trickling filter process
Rock (geology)
In geology, rock or stone is a naturally occurring solid aggregate of minerals and/or mineraloids.The Earth's outer solid layer, the lithosphere, is made of rock. In general rocks are of three types, namely, igneous, sedimentary, and metamorphic...
, gravel
Gravel
Gravel is composed of unconsolidated rock fragments that have a general particle size range and include size classes from granule- to boulder-sized fragments. Gravel can be sub-categorized into granule and cobble...
, slag
Slag
Slag is a partially vitreous by-product of smelting ore to separate the metal fraction from the unwanted fraction. It can usually be considered to be a mixture of metal oxides and silicon dioxide. However, slags can contain metal sulfides and metal atoms in the elemental form...
, peat moss, or plastic media over which wastewater flows downward and contacts a layer (or film) of microbial slime covering the bed media. Aerobic conditions are maintained by forced air flowing through the bed or by natural convection of air. The process involves adsorption
Adsorption
Adsorption is the adhesion of atoms, ions, biomolecules or molecules of gas, liquid, or dissolved solids to a surface. This process creates a film of the adsorbate on the surface of the adsorbent. It differs from absorption, in which a fluid permeates or is dissolved by a liquid or solid...
of organic compounds in the wastewater by the microbial slime layer, diffusion of air into the slime layer to provide the oxygen
Oxygen
Oxygen is the element with atomic number 8 and represented by the symbol O. Its name derives from the Greek roots ὀξύς and -γενής , because at the time of naming, it was mistakenly thought that all acids required oxygen in their composition...
required for the biochemical oxidation of the organic compounds. The end products include carbon dioxide
Carbon dioxide
Carbon dioxide is a naturally occurring chemical compound composed of two oxygen atoms covalently bonded to a single carbon atom...
gas, water and other products of the oxidation. As the slime layer thickens, it becomes difficult for the air to penetrate the layer and an inner anaerobic layer is formed.
The components of a complete trickling filter system are: fundamental components:
- A bed of filter medium upon which a layer of microbial slime is promoted and developed.
- An enclosure or a container which houses the bed of filter medium.
- A system for distributing the flow of wastewater over the filter medium.
- A system for removing and disposing of any sludge from the treated effluent.
The treatment of sewage or other wastewater with trickling filters is among the oldest and most well characterized treatment technologies.
A trickling filter is also often called a trickle filter, trickling biofilter, biofilter
Biofilter
Biofiltration is a pollution control technique using living material to capture and biologically degrade process pollutants. Common uses include processing waste water, capturing harmful chemicals or silt from surface runoff, and microbiotic oxidation of contaminants in air...
, biological filter or biological trickling filter.
Treatment of other organics
Synthetic organic materials including solvents, paints, pharmaceuticals, pesticides, coking products and so forth can be very difficult to treat. Treatment methods are often specific to the material being treated. Methods include Advanced Oxidation ProcessAdvanced Oxidation Process
Advanced oxidation processes refers to a set of chemical treatment procedures designed to remove organic and inorganic materials in waste water by oxidation...
ing, distillation
Distillation
Distillation is a method of separating mixtures based on differences in volatilities of components in a boiling liquid mixture. Distillation is a unit operation, or a physical separation process, and not a chemical reaction....
, adsorption, vitrification
Glass transition
The liquid-glass transition is the reversible transition in amorphous materials from a hard and relatively brittle state into a molten or rubber-like state. An amorphous solid that exhibits a glass transition is called a glass...
, incineration
Incineration
Incineration is a waste treatment process that involves the combustion of organic substances contained in waste materials. Incineration and other high temperature waste treatment systems are described as "thermal treatment". Incineration of waste materials converts the waste into ash, flue gas, and...
, chemical immobilisation or landfill disposal. Some materials such as some detergents may be capable of biological degradation and in such cases, a modified form of wastewater treatment can be used.
Treatment of acids and alkalis
Acids and alkalis can usually be neutralised under controlled conditions. Neutralisation frequently produces a precipitatePrecipitation (chemistry)
Precipitation is the formation of a solid in a solution or inside anothersolid during a chemical reaction or by diffusion in a solid. When the reaction occurs in a liquid, the solid formed is called the precipitate, or when compacted by a centrifuge, a pellet. The liquid remaining above the solid...
that will require treatment as a solid residue that may also be toxic. In some cases, gasses may be evolved requiring treatment for the gas stream. Some other forms of treatment are usually required following neutralisation.
Waste streams rich in hardness
Hard water
Hard water is water that has high mineral content . Hard water has high concentrations of Ca2+ and Mg2+ ions. Hard water is generally not harmful to one's health but can pose serious problems in industrial settings, where water hardness is monitored to avoid costly breakdowns in boilers, cooling...
ions as from de-ionisation processes can readily lose the hardness ions in a buildup of precipitated calcium and magnesium salts. This precipitation process can cause severe furring of pipes and can, in extreme cases, cause the blockage of disposal pipes. A 1 metre diameter industrial marine discharge pipe serving a major chemicals complex was blocked by such salts in the 1970s. Treatment is by concentration of de-ionisation waste waters and disposal to landfill or by careful pH management of the released wastewater.
Treatment of toxic materials
Toxic materials including many organic materials, metals (such as zinc, silver, cadmiumCadmium
Cadmium is a chemical element with the symbol Cd and atomic number 48. This soft, bluish-white metal is chemically similar to the two other stable metals in group 12, zinc and mercury. Similar to zinc, it prefers oxidation state +2 in most of its compounds and similar to mercury it shows a low...
, thallium
Thallium
Thallium is a chemical element with the symbol Tl and atomic number 81. This soft gray poor metal resembles tin but discolors when exposed to air. The two chemists William Crookes and Claude-Auguste Lamy discovered thallium independently in 1861 by the newly developed method of flame spectroscopy...
, etc.) acids, alkalis, non-metallic elements (such as arsenic or selenium
Selenium
Selenium is a chemical element with atomic number 34, chemical symbol Se, and an atomic mass of 78.96. It is a nonmetal, whose properties are intermediate between those of adjacent chalcogen elements sulfur and tellurium...
) are generally resistant to biological processes unless very dilute. Metals can often be precipitated out by changing the pH or by treatment with other chemicals. Many, however, are resistant to treatment or mitigation and may require concentration followed by landfilling or recycling. Dissolved organics can be incinerated within the wastewater by Advanced Oxidation Process
Advanced Oxidation Process
Advanced oxidation processes refers to a set of chemical treatment procedures designed to remove organic and inorganic materials in waste water by oxidation...
.
See also
- Aerated lagoonAerated lagoonAn aerated lagoon or aerated basin is a holding and/or treatment pond provided with artificial aeration to promote the biological oxidation of wastewaters. There are many other biological processes for treatment of wastewaters, for example activated sludge, trickling filters, rotating biological...
- ATP TestATP testThe ATP test is a process of rapidly measuring actively growing microorganisms through detection of adenosine triphosphate, or ATP.-ATP testing method:...
- Best management practice for water pollutionBest management practice for water pollutionBest Management Practices is a term used in the United States and Canada to describe a type of water pollution control. Historically the term has referred to auxiliary pollution controls in the fields of industrial wastewater control and municipal sewage control, while in stormwater management ...
(BMP) - Dark fermentationDark fermentationDark fermentation is the fermentative conversion of organic substrate to biohydrogen. It is a complex process manifested by diverse group of bacteria by a series of biochemical reactions involving three steps similar to anaerobic conversion...
- List of waste water treatment technologies
- Maceration (sewage)Maceration (sewage)Maceration, in sewage treatment, the use of a machine that reduces solids to small pieces in order to deal with rags and other solid waste. Also, macerating toilets, which use a grinding or blending mechanism to reduce human waste to a slurry, which can then be moved by pumping...
- Peak waterPeak waterThe term Peak Water has been put forward as a concept to help understand growing constraints on the availability, quality, and use of freshwater resources...
- Rotating biological contactorRotating biological contactorA rotating biological contactor or RBC is a biological treatment process used in the treatment of wastewater following primary treatment. The primary treatment process removes the grit and other solids through a screening process followed by a period of settlement...
- Sedimentation (water treatment)Sedimentation (water treatment)Sedimentation is a physical water treatment process used to settle out suspended solids in water under the influence of gravity.-Basics:Suspended solids , is the mass of dry solids retained by a filter of a given porosity related to the volume of the water sample...
External links
- Water Environment Federation - Professional society
- http://www.wockoliver.com/daf.html for industrial wastewater treatment based on DAF system
- http://www.wockoliver.com/packaged_treatment_plants.html for industrial wastewater treatment based on Package treatment plant or on MBBR technology.