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DEVELOPMENT AND CONSTRUCTON OF HIGH REMOVAL EFFICENCY

OF PATHOGENIC MICROBIAL ORGANISMS AND FLOURIDE WITH


LOW COST CERAMIC WATER FILTER FOR DEVELOPING COUNTRIES

Proposed by :- Alemayehu Solomon


ID NO. GSR/0141/09

Materials science and engineering Dec. 26- 12- 2017 G.c 1


1. INTRODUCTION
 Currently 0.7 and 1.8 billion people in the world do not have access to clean water
 WHO/UNICEF estimated that 57 % of Ethiopian households have access to improved

drinking water sources, but the remaining 43% do not have access.
 Ethiopian rural peoples rely on unimproved water sources, such as rivers, lakes,

ponds, streams, rainwater, unprotected springs and wells.


 About 3.4 million people, mostly children, die annually from water related

diseases. Out of this number, 2.2 million people die from diarrhoeal diseases
(including cholera) (Amenu, 2014).
 The tolerance limit of fluoride content of drinking water is 1.5 mg/L (WHO,

1993).
 Fluoride concentrations in the range (1.5-4) mg/L results in dental fluorosis

whereas with prolonged exposure within 4-10mg/L progresses to skeletal


fluorosis.
Materials science and engineering Dec. 26- 12- 2017 G.c 2
 WHO acknowledged several Household water treatment and safe storage (HWTS)
technologies for peoples who have no clean water sources nor adequate
infrastructure available.

Figure : the classification of HWTS technologies (WHO, Fane et al., 2011).

 Ceramic water filters would filter out most bacteria, viruses, sediments, VOCs, most
heavy metals, chlorine, radon, and reduce odor and bad tastes in water and it is the most
effective filtering media.
 To address drinking water related problems and to contribute to the manufacturing
and production understanding of CWFP, Thus, is chosen to be the focus of this project.

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1.1 STATEMENT OF THE PROBLEM

1. Around 80 % of Ethiopian peoples are living in rural areas and uses ponds, rivers and
lakes, streams, rainwater, unprotected springs and wells as a drinking water source,
which are highly contaminated.

 (43% of the total Ethiopian citizens and 51% of the rural population still depends on
unimproved drinking water sources for day to day activities. Even though some urban
peoples get supply of water through pipe, but it is almost not safe for drinking.)

2. High mortality rate due to water-borne disease in developing countries like Ethiopia. 60 %
-80 % mortality rate accounts to water-borne disease in Ethiopia.
 About 3.4 million people, mostly children, die annually from water related diseases.
Out of this number, 2.2 million people die from diarrhoeal diseases (including
cholera) (Amenu, 2014).
3. Ethiopian Central Rift Valley (ECRV), where an estimated 8 million people are exposed to
high levels of naturally occurring fluoride which results in both dental and skeletal
fluorosis .
4. Government and many NGOs are still spending a lot of money to alleviate this problem
each year.
5. Lack of cost effective house hold water treatment technologies in the market (in Ethiopia
only slow sand water filter technology is present and it is the most expensive one )
Materials science and engineering Dec. 26- 12- 2017 G.c 4
1.2 OBJECTIVE
GENERAL OBJECTIVE

 To develop the design and construct highly efficient ceramic pot water filter with
low cost, having high pathogenic microbial, fluoride and toxic metal removal
efficiency and provide safe drinking water to the whole low economic level
peoples of developing countries.
 By providing affordable water filters to third world countries will greatly improve
people’s quality of living, and reduce the risk of any waterborne diseases
therefore saving lives.
SPECIFIC OBJECTIVES
1. To determine the optimal ceramic water filter manufacturing process parameter range
according to pottery for peace (PFP, 2003) and engineers without borders (EWB,2009)
filter production requirement.
2. To develop design and construct both cement mold and manually driven jack hydraulic
filter press machine
Materials science and engineering Dec. 26- 12- 2017 G.c 5
3. To manufacture sample filter products and To determine average filtration rate,

physiochemical (including fluoride) and microbial removal efficiency both before and

after silver nitrate coating by using four different water samples.

 The result will be analyzed according to WHO (2006) and Ethiopian (2013) drinking

water guide lines.

4. To characterize raw materials (to find out their elemental chemical composition,

thermal analysis, crystal structure,) and final filter product ( to find out crystal structure

,thermal analysis and surface morphology)

5. To investigate the effect variation in combustible material, firing temperature and

particle size and coating silver nitrate solution on filter performance

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2. LITRATURE REVIEW
2.1 WATER BORNE PATHOGENS AND DISEASES

 The disease caused by water related microorganisms is divided into four main
classes (WHO, 2006) ; Water-borne diseases ,Water-related vector diseases,
Water-based diseases, and Water-scarce diseases.
 Water-borne diseases : caused by contaminated water by human, animal or
chemical wastes, thus are:-

o Bacteria (e.g. salmonella, shigella – causing bacillary dysentery, diarrhea,

typhoid, cholera etc),

o Viruses (hepatitis A, Hepatitis E, rotavirus etc), and

o Other parasites including protozoa (cryptosporidium, giardia, toxoplasma and

helminthes).
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2.2 OTHER DISEAS BY CHEMICAL CONTAMINANTS
Table : Fluoride concentrations that have exceeded more from WHO guideline
in the drinking 2.2.1
waterFLOURIDE AND FLOURISIS
source of different IN ETHIOPIA
parts of Ethiopia (Alemu et al. 2015)
 Ethiopian Central Rift Valley (ECRV), where an estimated 8 million people are exposed to
high levels of naturally occurring fluoride.
 Fluoride is found to be occur naturally as sellaite (MgF2), fluorspar (CaF2), cryolite (Na3AlF6)

and fluorapatite [3Ca3(PO4)2Ca(F,Cl)2] (Sushree et al. 2006).


 According to the World Health Organization (WHO), the tolerance limit of fluoride content
of drinking water is 1.5 mg/L (WHO, 1993).
 Fluoride concentrations in the range (1.5-4) mg/L results in dental fluorosis whereas with
prolonged exposure within 4-10mg/L progresses to skeletal fluorosis.

Materials science and engineering Dec. 26- 12- 2017 G.c 8


2.2 HOUSEHOLD WATER TREATMENT AND SAFE STORAGE OPTIONS
 WHO acknowledged several point-of-use technologies that bridges the shortages
of different infrastructures. These technologies fall into three categories:

e.g Ceramic water filter


Figure: the classification of HWTS technologies (WHO, Fane et al., 2011).

Log Reduction Value (LRV)


(Bielefeldt et al., 2010).
 Categories for microbial efficacy are <1 log10 (<90%) is low, 1to 2 log10 (90-99%) is moderate and >2
log10 (>99% is high).
Materials science and engineering Dec. 26- 12- 2017 G.c 9
2.3 CERAMIC FILTERS AS HWTS
 Three
 Ceramicmain
watergeometrical
filters are porous clay pots
shapes that water
are often can flow
reported and through,
adopted while preventing
in literature: disk,
solid material,
candle bacteria and
and pot/frustum some viruses
geometrical from (Dies
shapes passing2003,
through.
Simonis and Basson,
 These filters are typically made from a mixture of clay and a combustible material
2011; 2013).
(sawdust, coffee husk, rice husk etc.),

 The raw materials that are used for producing CWF’s are in abundance and
ecofriendly, and low cost.

Figure : Geometrical Classification of ceramic water filters

Materials science and engineering Dec. 26- 12- 2017 G.c 10


Fundamentals of clay minerals

Figure : The different layer structures. (A) The 1:1 layer; (B) the 2:1 layer; (C) the 2:1 layer
with anhydrous interlayer cations;(D) the 2:1 layer with hydrated interlayer cations; (E) the
2:1 layer with octahedral interlayer sheet (Brigatti et al,2013).
Materials science and engineering Dec. 26- 12- 2017 G.c 11
Table : Applications of clays for remediation of polluted water, pollution
control, and environmental protection (Yuan et al, 2013).

 In this context, the present thesis work has the purpose to investigate the possibility to use
natural clays as low cost sorbents for CPWF..
Materials science and engineering Dec. 26- 12- 2017 G.c 12
2.3.1 MECHANISMS OF FILTRATION IN POROUS MEDIA

Figure: Schematic diagram of the types of pores (Xiaolong 2005)


 The phenomena that enhance the removal of impurities in the filtration process include;

I. Mechanical screening:
II. Sedimentation(precipitation)
III. Diffusion :
IV. Adsorption:
V. Chemical activity
V. Biological activity:

Figure : Schematic diagram of the mechanism of filtration (van halem 2006).


 
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 The properties of different types of metallic metals and metallic oxides such as
copper, silver and zinc, and their mechanism of action as antimicrobial, antifungal
and antiviral agents is given below.
 The ceramic water filter utilizes the following modes of action to deactivate
microorganisms:
I. Catalytic oxidation
II. Catalytic reduction/oxidation :
III. Reaction of silver ions with bacterial cell membrane:
 The order of antimicrobial activity of metal oxides was demonstrated as follows
AgO > ZnO > CuO > FeO (Azam et al., 2012).
 Due to its efficiency and effectiveness, Silver nitrate (AgN03) (99.98% purity)
solution is selected as a coating anti biocide solution than any other metal oxides
solutions
Materials science and engineering Dec. 26- 12- 2017 G.c 14
2.3.2 FACTOR AFFECTING FILTER PERFORMANCE
Porosity
(Yoko et al., 2002).

Water Quality Water Turbidity


(Matteiletea, 2006) (Lantagne, 2001).
Factor affecting
filter
performance

Water Pressure Filter Thickness


(Franz, 2004). (Franz, 2004).

Filter Surface Area


(V.Halem, 2006)

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2.3.3 ANALYTICAL MODEL ON FILTRATIO RATE OF CPWF
 The analytical model of the
discharge (the laminar flow
rate) through the filter is
based on the Darcy's law
(Bear 1972).
𝑲 𝐀 𝐏
𝑸=
𝑳 µ
𝐏=𝝆 𝐠(𝒉 ( 𝒕 ) − 𝒚 ) 𝒓 ( 𝒚 )= 𝑹+𝒚𝒕𝒂𝒏 𝜽 𝐴=𝜋 𝑟 2

The overall flow rate of the filter Qtotal l,

is give by the summation of Qb and Qs

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2.4 PREVIOUS RESEARCH ON CPWF PERFORMANCE
 Protozoa, such as Giardia lamblia and Cryptosporidium parvum, exist in the
environment as cysts and oocysts respectively and are relatively large in size (>4 µm).
 A Nicaraguan filter challenged with water spiked with Cryptosporidium parvum and
Giardia lamblia achieved a 4-log reduction for both protozoa (Lantagne 2001a).but
Cryptosporidium parvum is resistant to chlorination.
 Similar results were obtained for the removal of sulphite reducing Clostridium oocysts for a
ceramic water filter produced in Nicaragua (van Halem 2006).
 An overview of the bacterial and viral testing of low-cost Ceramic Pot Filters (CPF), as
presented by Simonis and Basson (2011), gives an average Log Reduction Value (LRV) of
2.0 (99% reduction) for Escherichia coli over the listed 15 laboratory and field studies.
 This complies with the performance target indicated as ‘Protective’ as set by the WHO
(WHO, 2011) for bacteria.

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Table : Summary Bacteria removal efficiency of CPWF from different Field Studies

 Limitations to this theory are that stored water might not be from the same source
as filtered water (Brown et al. 2007).
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 Resource Development International— Cambodia (RDI-C) adds laterite, which is rich
in goethite and other iron oxides, to their filter mixture (Hagan et al. 2009) and
although a 1-2 LRV (90%-99%) in MS2 was measured,
 Filters manufactured with increased laterite content (which also increased the flow
rate) did not show improved viral removal efficiencies; the mean LRV was less than
0.5 .Filters with increased laterite were also heavier and more porous which might
increase breakage and affect user acceptability (Bloem et al. 2009).
 In one study in Cambodia, filter users reported a 49% reduction in diarrhea as
compared with non filter users (Brown et al. 2008) and in another study a 46%
reduction was reported (Brown et al. 2007 and WHO 2007).
 Virus removal efficiency of ceramic pot filters does not meet the WHO standards for
being ‘Protective’ (LRV 3; WHO, 2011). No critical parameter is yet found to
enhance the virus removal efficiency (H. van der Laan et al., 2014).
Materials science and engineering Dec. 26- 12- 2017 G.c 19
Testing done on low cost ceramic water filter (CWF) effectiveness in bacterial
and viral removal for period 2000-2010 are given in table below

Some literature on bacterial and viral testing adopted from Simons et al.
(2011)
Materials science and engineering Dec. 26- 12- 2017 G.c 20
 If the proportion of sawdust is changed in the mixture, the flow rate will also be affected
because of the changes in geometry of the pores formed (Dies 2003; Davies et al., 2010).
 The pore diameter from literature for most ceramic water filters has been found to be
within the range 0.2-2.5 µm.
 Filters manufactured using a larger screen size to sieve the sawdust has been shown to
reveal no significant difference in flow rates (Klarman 2009).
 At certain factories, however, filter mix ratios are adjusted to achieve acceptable flow rate
ranges according to the particle size of the rice husks received, adding more rice husk to
the mixture if filtration rate is observed to be smaller (Hagan et al., 2009).
 In addition, the use of different burn-out materials, even when sifted to the same screen
size, can increase the flow rate but may also reduce total coliform removal efficiency. This
emphasizes the need to develop a new ratio when changing the burn-out material
(Klarman 2009).
 As the mixed ratio and density of the combustible material is increased, there is increased
probability that pores may become connected, and larger than desired (Klarman, 2009;
Lantagne 2010).
 The size, the type and amount of the combustible material filtration rate; clay type will
also affect the filter’s hydraulic conductivity and removal efficiency(Oyandel-Craver 2008).

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 DE-fluoridation is the process of removal of fluoride ion that is found in water.
 Among these methods, adsorption is still one of the most extensively used, because of its
simplicity and the availability of a wide range of adsorbents.
 The main methods used in defluoridation from aqueous solutions are membrane
techniques and adsorption techniques (alumina based adsorbents, Clays and Soils, Carbon,
Zeolites and layered double hydroxides ,M. Mohapatra et al. 2009).
 A large number of materials have been tested for defluoridation, such as, activated alumina,
amorphous alumina, activated carbon, calcite, red mud and rare earth oxides (Jamode et
al., 2004; Wang et al., 2009).
 In developing countries like Ethiopia, bone char (implemented by the local NGO, Oromia Self
Help Organization (OSHO) )and the Nalgonda(by UNICEF and the Federal Water and Energy
Ministry (FWEM) since 2005) technique are the most common methods used for the removal
of fluoride from drinking water (WHO, 2004).
 Bone char filters are made of powdered cow bones. The principal active component of bone
char is Ca3 (PO4)2, 57- 80 %, CaCO3 6- 10 % and activated carbon 7-10 % (Fawell et al., 2006).
 Bone char filters (Charring animal bones) removes organic matter from the bone structure,
producing a large specific surface area which is helpful for high adsorption capacity
(Chidambaram et al., 2004; Kaseva, 2006).
 Disadvantage of using bone char is it requires much larger dose of alum, low removal
efficiency and has problems associated with large sludge disposal (Shrivastava and Vani,
2009).
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 The Nalgonda technique utilizes aluminium sulphate that sorb and settle fluoride
ions based on coagulation-flocculation-sedimentation, where the dosage is
designed to ensure F – ion removal from the water.
 its disadvantage is it requires frequent addition of chemicals, produces copious
amounts of waste sludge, and is not efficient for fluoride removal when the
starting concentration is high (Fawell et al., 2006; Nigussie et al., 2007).
 De-fluoridation based on membrane methods is used in developed countries for
drinking water treatment includes reverse osmosis (Min et al., 1984),
nanofiltration (Tahaikt et al., 2007), electrodialysis (Nalan et al., 2008) and electro
coagulation (Sanjeev et al., 2009).
 It requires more technical support for operation, maintenance and high capital
investment cost, and high energy consumption.

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 Ultraviolet treatment is the best method to inactivate bacteria and viruses, but not
very effective on other contaminates. Ultraviolet treatment is also expensive.
 Reverse osmosis filters eliminate most contaminates, but its cost is relatively high so
that it is not affordable third world countries,
 Slow sand (Biosand)filters are economical and material is also easily obtained.
However, it only operates properly in large size. This is not viable for a typical home
use water filter.
 The ceramic filter systems are the most effective household water treatment than
Biosand, Solar Disinfection (SODIS) and chlorination, especially on the long term
Hunter (2009).
 Ceramic water filters would filter out most bacteria, viruses, sediments, most heavy
metals, fluorine, radon, and reduce odor and bad tastes in water and it is the most
effective filtering media. Thus, is chosen to be the focus of this project.
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RESEARCH GAP ON CPWF(Unresolved issues regarding on CPWF)
1. The investigation in this project will be carried out from raw material to the final
product will be analyzed to arrive right conclusion
2. The influence of the microstructure on the filter product performance is not
analyzed in any paper before
3. The effect of variation of combustible materials, particle size, and firing
temperature on filter performance is not analyzed together
4. It just for the first time CPWF is analyzed for DEFLUORIDATION
5. Low cost design development and construction of both the cement mold and
jack hydraulic filter press is also the first time in Ethiopia
6. Finally, it just for the first time in Ethiopia CPWF to be fabricated practically and
to analyze both physiochemical and microbiological removal efficiency
 This project is expected to solve a country level problem. Beside to these, it just
to contribute to the manufacturing and production understanding of CPWF.
Those are the main reason why this project is chosen.
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METHODOLOGY
1.The methodology
EVALUATIONS OF of this project
OPTIMUM is MANUFACTURING
FILTER mainly aimed to follow the
PARAMETERS
fundamental principle of material processing .this can be described
I. Test for the Water of Plasticity
as:
 This test determines the amount of water required for clay to become workable, of the
PROCESS
desired consistency.structure property performance
II. Shrinkage
Achieving optimum
filter performance
Achieving pre- ( i.e optimum
determined filtration rate,
Implementing a
microstructure of physiochemical
pre-determined
the final filter and microbial
raw material
 Knowing the total shrinkage
Identifying the rate of the filter mixture will be useful for designing molds of
product(the removal efficiecy)
physical and Processing
the proper dimensions so that after firing the filter element will fit precisely inside the
available receptacle(amount of size ,amount and
mechanical kind of distribution
III. Percent
property mixing ratio,
of theAbsorption (Porosity) of porosity in the
raw drying and firing
 Thematerials filter)
degree of water absorption of the fired clay, or percentage porosity, is also a
T°c etc.)
measure of the maturity of a fired clay body.
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2. DEVELOPING DESIGN AND CONSTRUCTION OF BOTH CEMENT MOLD
AND FILTER PRESS MACHINE

I. CEMENT MOLD DESIGN

Figure: AUTO CAD 2010 filter design and its dimensions

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Figure: flat cement mold and CPWF design
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II. LOW COST JACK HYDRAULIC FILTER PRESS DEVELOPMENT

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3. CERAMICS POT WATER FILTER (CPWF) SAMPLE PREPARATION TECHNIQUE
Pulverizing, sieving,
milling and drying
of clay raw
materials

Pulverizing, sieving, Firing Pure


Mixing
Filter Surface Air water
milling and drying ingredient wedging green
pressing finishing drying soaking
of combustible raw powder filters
materials CPWF
product
Pulverizing, sieving, Pre-
milling and drying Physiochemical
of grog( fired brick) testing Pre-Flow
Preparatio
Coated Coating n of silver rate
Filter
Filter AgN03 nitrate testing
drying
drying
solution biocide Pre-
solution Microbiological
testing
Post-
Physiochemical
testing
Pre-Flow
rate finish
testing
Post-
Microbiological
testing

Figure : CWFP production and filter performance tests

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4. CHARACTERIZATION TECHNIQUE
I. POWDER X-RAY DIFFRACTION (XRD) ANALYSIS :
 X ray powder diffractometer (XRD- 7000S, Dangil shimadzu) to analysis the crystal
structure of the powder of ansho and babuwoha kaolin clay powder, grog (unfired brick),
laterite and fired filter product powder samples

II. SCANNING ELECTRON MICROSCOPY (SEM) ANALYSIS :

 The surface morphology analysis of CPWF product sample were carried out using a
NOVA NANO SEM 230 (FEI) scanning electron microscope with the VCD detector in
high vacuum.
 Samples will be sputter coated with gold to reduce static charging just before SEM
analyses.
 In addition to the morphological analysis, the elemental composition of CPWF
product sample will be analyzed by Energy dispersive spectroscopy(EDS) which
works coupling to SEM device
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III. DIFFERENTIAL THERMOGRAVIMETRIC(DTG) ANALYSIS

 The thermal stability and fraction of volatile components of ansho and


babuwoha kaolin clay powder, grog (unfired brick), laterite and fired filter
product powder samples will carried out in air by using a Dangil shimadzu
DTG-60 instrument in the temperature range of 30-900°C and at a heating
rate of 20°C/min by taking sample of 4 to 5 mg weight.

Materials science and engineering Dec. 26- 12- 2017 G.c 32


5. FILTER PERFORMANCE TESTING METHODS
I. Filtration Rate Test:
 First all CPWF samples will be soaked in pure distilled water
containing bow plastic container for 24 hours.
 Then each filter sample elements will be tested by using T-device
(T- shaped pipe having mili liter mark on it).
 Flow rate will be easily determined, reading the volume of water
level drop on T- device per an hour.

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II. Physiochemical Removal Efficiency Test
 The major physicochemical parameters will be analyzed in Mojo Nalgoda
water quality analysis research institute.
 Temperature and pH was analyzed using portable digital pH meter (Jenway mode
370, England).
 Total dissolved solids (TDS) and electrical conductivity were analyzed using
portable digital conductivity meter (CC-401, Poland).
 Turbidity by using portable microprocessor turbidity meter (H193703 ELE
international, Hungary)
 Dissolved oxygen (DO) by using waterproof oxygen meter (CO-411, Poland).
 Free residual fluorine and chlorine test by using Portable comparator disk
(Wagtech, UK)
 Nitrate and phosphate was measured using HACH DR/2010 spectrophotometer.

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III. Microbiological Removal Efficiency Test
 With regard to bacteriological parameters, samples were analyzed
using membrane filtration (MF) method for water quality to
determine the degree of contamination (WHO, 2006; APHA, 1998).
 This test will be carried out in Oromia water mineral and energy
bureau water quality control laboratory, which is found in Adiss
Ababa town, capital city of Ethiopia.
 It is around 89 km far from Nazret (Adama) town and takes one hour
on the main road.
 Four water samples were analyzed for the presence of total coliforms (TC), faecal
coliforms (FC) and faecal Streptococci (FS).
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EXPECTED RESULT
1. The microbial removal efficiency is expected to fall in between 99-99.99 % that
means from 0-100 CFU/ 100ml of both E.coli and total coliform.

2. Its physiochemical analysis result is expected to have color < 15 TFU, turbidity <5
NTU, residual fluoride concentration <1.5 gm/lit, hardness <300 mg/lit as
CaCo3,its PH 6.5 – 8.5, Residual chlorine <0.5 gm/lit, and Total dissolved solids
(TDS) <1000 mg/lit,

3. Its porosity result is expected to fall in between 30%- 44% and its filtration rate
1-3 lit/hr which will be sufficient for eight member family for access of around
36 liter safe drinking water per a day.

4. The overall expected result is expected to satisfy all the requirement of Ethiopian
(2011) and WHO (2006) standard drinking water guide line and to get legally
qualified certificate for CPWF product as national level.
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3.1 Tentative time schedule
TENTATIVE TIME SCHEDULE
Task January February March April
name
Week Week Week Week Week Week Week Week Week Week Week Week Week Week
1 2 3 4 1 2 3 4 1 2 3 4 1 2
`evaluating process
prameters
Preparation of
cement mold
Construction of jack
hydraulic filter press

Preparation of
CPWF samples

Raw material and


product
Characterization
Pre-filtration rate
test

Dilute silver nitrate


preparation and
application
Post- filtration rate
test

Physiochemical
removal efficiency
test
Microbiological
removal efficiency
test
Finishing Project
Paper work

Note that: project running schedule is designed according to post graduate academic
calendar.

Materials science and engineering Dec. 26- 12- 2017 G.c 37


Materials science and engineering Dec. 26- 12- 2017 G.c 38

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