Water recycling and water reuse

integral part of industrial water

management

Peter Cornel
Technische Universitt Darmstadt, Germany
Institute....

Structure
Introduction / water challenges
Water consumption and water resources
Resources in wastewater
Water itself
Energy in wastewater
Nutrients and other valuables

Steps for implementation of water reuse

Examples (not included in handout)
Conclusion

Challenge I: World Population Growth

Actual and Projected

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Challenge II: Urbanization

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Challenge II: Urbanization

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Challenge II: Urbanization

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Challenges III: Limited resources

1. Water

2. Energy

http://www.hvv-mobility.com 26.5.2013

Jialing/Chongqing 2006; www.zeitenschrift.com/magazin/54wasser.jpg 26.5.2013

3. Nutrients (P, N, ..)

www.baecktrade.de 26.5.2013

TU Darmstadt, Germany | Institute IWAR | Peter Cornel |

Source: A.J.B. Zehnder, Dechema 2003,

Annual water requirement per person

Sufficient
Water stress
Scarcity
Extreme scarcity
Source: A.J.B. Zehnder (EAWAG), Dechema, May 2003

> 1700 m3
1000 - 1700 m3
500 - 1000 m3
< 500 m3

Water needed to produce 1 kg of plant material

(dry weight)
Sorghum
Corn
Clover
Wheat
Potatoes
Cucumber
Alfalfa

250
350
460
500
636
713
900

Liter
Liter
Liter
Liter
Liter
Liter
Liter

Rule of thumb:
For 1kg of bread 1m3 water is needed
Source: A.J.B. Zehnder (EAWAG), Dechema, May 2003

Animals convert 5 to 15 percent of the

energy content of plant material into meat.
The average is 10 percent.

Rule of thumb:
10 times more water is needed per unit of
energy from meat than from plants
Source: A.J.B. Zehnder (EAWAG), Dechema, May 2003

Annual per capita water needs for food

to cover 2500 kcal a day

20% meat:
theoretical 680 m3
actual 1200 - 1500 m3
Source: A.J.B. Zehnder (EAWAG), Achema, May
2003

Vegetarian:
theoretical 250 m3
actual 500 - 1000 m3

Solving water shortage problems

Integrated water resource management
Sustainable, ecologically, economically

Efficient use needs

Improved management
Improved technology
Adequate tariff structures

Import from external sources as virtual water

Virtual water trade organization
Water intensive industries in water rich regions

Use of additional sources:

Use of runoff water / Rainwater Harvesting
Saline water / sea water high energy consuption (3-4 kWh/m)
Treated wastewater / water reuse ( 1 kWh/m)

Wastewater is ambivalent

resource
potential and kinetic energy

phosphorus
potassium

heat

organic carbon

nitrogen
pathogens
germs
viruses
helminth eggs

zinc
copper iron

pollutant

AOXs
PCBs

water

PAHs

endocrine disrupters antibiotics

contraceptives
hormones

unknown
unknowns

Resource or pollutant?
A Question of the point of view

Resource
as
fertilizer

Phosphorus
Potassium

resource
potential and kinetic energy
heat

organic carbon

Nitrogen
pathogens
germs
viruses
helminth eggs

zinc
copper iron

pollutant

AOXs
PCBs

water

PAHs

endocrine disrupters antibiotics

contraceptives
Eutrophication
Oxygen
depletion

hormones

unknown
unknowns

Resource or pollutant?
A Question of the point of view

Resource

Phosphorus
Potassium

for
energy

resource
potential and kinetic energy
heat
Organic carbon

Nitrogen

endocrine disrupters
antibiotics

pathogen
germs
s
viruses
helminth
eggs

water

zinc
copper iron

pollutant

Oxygen
depletion

AOXs
PCBs

contraceptives
hormones
Eutrophication,

PAHs

unknown
unknowns

Resource or pollutant?
A Question of Concentrations

Wastewater
contains
99.5% water

Phosphorus
Potassium

resource
potential and kinetic energy

organic carbon

heat

Nitrogen

endocrine disrupters
antibiotics

pathogen
germs
s
viruses
helminth
eggs

Water

zinc
copper iron

pollutant

AOXs
PCBs

PAHs

contraceptives
hormones

unknown
unknowns

Reuse is more than water reuse

Reuse options
Water (fit for purpose)
Within the same process (direct recycling)
Downgrading /Upgrading
Cooling

Energy
Caloric energy / heat recovery
Chemical bound energy, e.g. via COD Biogas CHP power + heat

Compounds

Nutrients
Metals
Solvents
.

Fit for purpose

Quality requirements depend on utilization of water reuse
Possible relevant parameters:
Salts (Calcium-, Magnesium-, Sodium-, Iron-, Alumina-, )
Hygienic condition (pathogens, helminth eggs, etc.)
nutrients (biofilm formation, re-growth of microorganisms)
Color, odor
Inorganic and organic trace elements

Advanced treatment options:

Filtration for particle removal (and biodegradation)
Activated carbon/ Ozonation for organic trace elements
Disinfection for pathogens
Membrane filtration (particle removal, disinfection to desalination)

Steps for implementation of reuse

Not different from industrial water management in general
1. Inventory of existing water management

Water consumers (amount, quality needed,)

Wastewater producers (amount, quality, specifics, valuables,

temperature, )

Added chemicals which might be in wastewater streams from process

or at WWT (reactants, flocculants, salts, acid/base, cleaning agents,
)

2. Make a water balance

3. Identify trouble makers (salt, color, toxic compounds, )

TU Darmstadt, Germany | Institute IWAR | Peter Cornel |

20

Steps for implementation of reuse

4. Identify reuse / recycling options

Within the same process

For other processes (downgrade)
For external users
From outside e.g. reclaimed water or municipality

5. Partial streams or full stream

6. Check

Amounts (hour, day, year,..)

Availability when needed (variations in demand and availability
Quality requirements (fit for purpose, tolerable /non-tolerable comp.)
Legal requirements

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21

Steps for implementation of reuse

7. Evaluate treatment options

Possible treatment techniques

Feedback on water quality and balances
GHG and Energy balances
Combination with resource recovery possible?
Economics

Cost for reuse (Opex, Capex)

Savings in freshwater, WWT and energy

8. Tests / experiments if necessary

9. Implementation

10. Monitoring and optimization

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22

Reuse options (examples)

Low contaminated water for cleaning and rinsing processes with
low quality requirements (Downcycling / Down grading)
(with or without intermediate treatment)
Cleaning and rinsing water recycling with intermediate mechanical
/ biological treatment
Desalinated process water after treatment for make-up-water in
cooling towers or as boiler feed water
Treated wastewater as make-up water for cooling towers (after
desal)

Potential risks
Bacteriological pollution
measure: disinfection
chemically
electro-chemically
membrane processes

salting
measures
Reverse osmosis (RO)
Ionen exchange

Increase of non-degradable organic compounds

measures
Oxidation
Adsorption
Nanofiltration, RO

Industrial Water Use in Germany in 106 m/a

origin

number
of firms

Freshwater

Water
usage

Cooling
water

Utility
factor
(# of recycle)

10.305

6.207

30.226

22.486

4,9

794

3.422

11.836

10.594

3,5

1.366

873

6.018

4.925

6,9

467

610

3.485

816

5,7

2.345

416

1.728

834

4,2

59

244

2.379

2.301

9,7

- automotive

449

93

1.989

1.092

21,5

- textile- and garment

483

183

242

172

1,3

processing industry
- chemistry/pharmacy.
- metal
- pulp and paper
- food
- coke oven/mineral oil

[Statistisches Jahrbuch 2001]

Specifc water amount in paper industry

l/kg Paper
50

(average all products)

40

30

20

10

0
1974 1976 1978 1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002
Quelle: F. Schmid, PTS-Mnchen

Energy for water

Source
Supply and
Conveyance
0 1.06 kWh/m

Water Treatment
0.026 4.23 kWh/m

Water Distribution
0.18 0.32 kWh/m

Recycled Water
Recycled Water
Distribution
Treatment
Verteilung
0.11 0.32 kWh/m
Discharge
0 0.11 kWh/m

Receiving
water

Wastewater
Treatment

Wastewater
Collection
0.29 1.22 kWh/m

Total water use cycle energy intensity (without end

use energy demand)
0.53 5.3 kWh/m

22.09.2013 | Fachbereich Bauingenieurwesen und Geodsie | Institut IWAR | Prof. Dr. -Ing. Cornel | 27

User
Household:
< 20 kWh/m
Industry:
??? kWh/m

source: Integrated
Energy policy report
2005, modified

(intermediate)-treatment processes
In general all known processes
typically pilot tests required / recommended
Multi barrier treatment, e.g.
Biological treatment (degradable COD)
Oxidation
(non-degradable Cod)
Membrane processes

Disinfection (UF/MF)
Particles (UF/MF)
Disolved organics (NF)
Desalination(RO)

Membrane processes are a breakthrough technology for reuse

Examples
Examples will be presented
Membrane bioreaactor plants for effluent treatment
Reuse of secondary municipal effluent in refinery
Reuse of refinery effluent within refinery

TU Darmstadt, Germany | Institute IWAR | Peter Cornel |

29

Water recycling and water reuse

integral part of industrial water
management

Peter Cornel
Technische Universitt Darmstadt, Germany
Institute....
www.iwar.bauing.tu-darmstadt.de