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Industrial wastewater treatment covers the mechanisms and processes used to treat wastewater that is produced as a by-product of industrial or commercial activities. After treatment, the treated industrial wastewater (or effluent) may be reused or released to a sanitary sewer or to a surface water in the environment. Most industries produce some wastewater although recent trends in the developed world have been to minimise such production or recycle such wastewater within the production process. However, many industries remain dependent on processes that produce wastewaters.
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Treatment of industrial wastewater
The various types of contamination of wastewater require a variety of strategies to remove the contamination.
Brine treatment
Brine treatment involves removing dissolved salt ions from the waste stream. Although similarities to seawater or brackish water desalination exist, industrial brine treatment may contain unique combinations of dissolved ions, such as hardness ions or other metals, necessitating specific processes and equipment.
Brine treatment systems are typically optimized to either reduce the volume of the final discharge for more economic disposal (as disposal costs are often based on volume) or maximize the recovery of fresh water or salts. Brine treatment systems may also be optimized to reduce electricity consumption, chemical usage, or physical footprint.
Brine treatment is commonly encountered when treating cooling tower blowdown, produced water from steam assisted gravity drainage (SAGD), produced water from natural gas extraction such as coal seam gas, frac flowback water, acid mine or acid rock drainage, reverse osmosis reject, chlor-alkali wastewater, pulp and paper mill effluent, and waste streams from food and beverage processing.
Brine treatment technologies may include: membrane filtration processes, such as reverse osmosis; ion exchange processes such as electrodialysis or weak acid cation exchange; or evaporation processes, such as brine concentrators and crystallizers employing mechanical vapour recompression and steam.
Reverse osmosis may not be viable for brine treatment, due to the potential for fouling caused by hardness salts or organic contaminants, or damage to the reverse osmosis membranes from hydrocarbons.
Evaporation processes are the most widespread for brine treatment as they enable the highest degree of concentration, as high as solid salt. They also produce the highest purity effluent, even distillate-quality. Evaporation processes are also more tolerant of organics, hydrocarbons, or hardness salts. However, energy consumption is high and corrosion may be an issue as the prime mover is concentrated salt water. As a result, evaporation systems typically employ titanium or duplex stainless steel materials.
Brine management
Brine management examines the broader context of brine treatment and may include consideration of government policy and regulations, corporate sustainability, environmental impact, recycling, handling and transport, containment, centralized compared to on-site treatment, avoidance and reduction, technologies, and economics. Brine management shares some issues with leachate management and more general waste management.
Solids removal
Most solids can be removed using simple sedimentation techniques with the solids recovered as slurry 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 polyelectrolytes.
Oils and grease removal
The effective removal of oils and grease is dependent on the characteristics of the oil in terms of its suspension state and droplet size, which will in turn affect the choice of separator technology.
Oil pollution in water usually comes in four states, often in combination:
The methodology for separating the oil is dependent on the oil droplet size. Larger oil droplets such as those in free oil pollution are easily removed, but as the droplets become smaller, some separator technologies perform better than others.
Most separator technologies will have an optimum range of oil droplet sizes that can be effectively treated. This is known as the "micron rating."
Analysing the oily water to determine droplet size can be performed with a video particle analyser. Alternatively, there are commonalities in industries for oil droplet sizes. Larger droplets–greater than 60 microns–are often present in wastewater in workshops, re-fuel areas and depots. Twenty to 50 micron oil droplets often are present in vehicle wash bays, meat processing and dairy manufacturing effluent and aluminium billet cooling towers. Smaller droplets in the range of 10 to 20 microns tend to occur in workshops and condensates.
Each separator technology will have its’ own performance curve outlining optimum performance based on oil droplet size. the most common separators are gravity tanks or pits, API oil-water separators or plate packs, chemical treatment via DAFs, centrifuges, media filters and hydrocyclones.
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 solvents 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 plants, and natural gas processing plants 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 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.
Hydrocyclone oil separators operate on the process where wastewater enters the cyclone chamber and is spun under extreme centrifugal forces more than 1000 times the force of gravity. This force causes the water and oil droplets to separate. The separated oil is discharged from one end of the cyclone where treated water is discharged through the opposite end for further treatment, filtration or discharge.
Hydrocyclones are useful for the greatest range of oil droplet sizes operating from less than 10 microns and up and can operate continuously without water pre-treatment and at any temperature and pH. Applications where hydrocyclones are found are in industry where oily water sources arise in workshops, vehicle wash bays, transport hubs, fuel depots and aluminium billet processing. Animal fats from meat processing and dairy manufacturing can also be removed without the need of chemical treatment that often is required for dissolved air flotation (DAF) systems.
Removal of biodegradable organics
Biodegradable organic material of plant or animal origin is usually possible to treat using extended conventional sewage treatment 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 undiluted blood or milk. The presence of cleaning agents, disinfectants, pesticides, or antibiotics can have detrimental impacts on treatment processes.
Activated sludge process
Activated sludge is a biochemical process for treating sewage and industrial wastewater that uses air (or oxygen) and microorganisms to biologically oxidize organic pollutants, producing a waste sludge (or floc) containing the oxidized material. In general, an activated sludge process includes:
Trickling filter process
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 fundamental components of a complete trickling filter system are:
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.
Treatment of other organics
Synthetic organic materials including solvents, paints, pharmaceuticals, pesticides, products from coke production and so forth can be very difficult to treat. Treatment methods are often specific to the material being treated. Methods include advanced oxidation processing, 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.
Treatment of acids and alkalis
Acids and alkalis can usually be neutralised under controlled conditions. Neutralisation frequently produces a precipitate that will require treatment as a solid residue that may also be toxic. In some cases, gases 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.
Treatment of toxic materials
Toxic materials including many organic materials, metals (such as zinc, silver, cadmium, 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 the advanced oxidation process.