Case Study of A Textile Arulpuram

CETP
P R E S E N T E D B Y:

PAT E L Y O G E S H D . ( 1 6 C H 6 0 R 5 8 )

Department of Chemical Engineering

Indian Institute of Technology, Kharagpur

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Outline
ZLD
CETP Treatment Scheme
Unit
Problem associated with this process
Proposed solution
Revised treatment scheme
Case study
Conclusion
Refrences

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Status of CETP’s in India

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 ZLD
ZLD – meaning zero discharge of waste water from
Industries.
A ZLD system involves a range of advanced
wastewater treatment technologies to recycle, recovery
and re-use of the ‘treated’ wastewater and thereby
ensure there is no discharge of wastewater to the
environment.
A typical ZLD system comprises of the following
components:
1. Pre-treatment (Physico-chemical & Bio.
2. Reverse Osmosis (Membrane Processes)
3. Evaporator & Crystallizer (Thermal Processes)

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CETP Treatment Scheme

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 Some unit of the process

Storage & Homogenization Tank: BIOT Ultra Filtration

Reverse Osmosis Reactor Clarifier

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Problem associated with this process
No glauber Salt crystallization.
Reduced recovery in MVR required additional MEE stages and an Adiabatic
Chiller to achieve desired feed volume, recovery and concentration to achieve
crystallization.
Inability to handle BDTRF (decolorant and Softener resin regenerate) liquor
due to choking of the polymeric heat exchangers due to higher hardness and
organics.
Based on the above situation it was estimated that two streams of Seven effect
Evaporators for MVR concentrate and BDTRF+Chiller Mother liquor will be
required which will not only increase the capital cost by Rs. 10 Crores per MLD
but also increase the operating cost to Rs. 300-350 per m3 of reject for
evaporation and crystallization.

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Conti….
R.O Rejects contain Hardness, Organics, Silica and other contaminants
which affect Evaporator performance as their concentration increases
during evaporation.
Possibility of salt produced being contaminated with above contaminants.
Waste salt disposal is an issue.
High Scaling (due to hardness) and corrosion (due to chlorides) resulting
in poor performance and life of equipment.

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Proposed Technological Solution
Direct re-use of Treated brine is proposed as a solution to the problem.
 This has the following advantages:
 Eliminates large additional modifications required to make the
Evaporator functional.
 Reduces O&M cost by about Rs. 50/Kl
 Reliable and Easy to operate Technology.
 Various components of the Technology proposed after extensive pilot
trials.
 Successful dyeing Trials done in all CETPs and bulk operations
done in 3 CETPs in 30 dyeing units using water tankers for
transportation.

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REVISED TREATMENT SCHEME

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 Case Study of A Textile Arulpuram CETP
Design Capacity: 5500 m3/d Project Status: Phase I modifications
completed. Phase II
ongoing.
No. of Member 15 Original Cost of 55 Crores
Units: Project:
Type of Dyeing: Knitted fabric Additional Cost Rs. 15 Cr
(mainly cotton) for Modifications:

Current processing 3850 m3/d Current Status: Operating successfully

capacity: (70%) under ZLD mode at 70% of
design Capacity
Date of Commencement of ZLD 24th Aug’ 2011
demonstration:
Current Status: Operating successfully under ZLD mode at 70%
of design Capacity

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Combined Effluent Characteristics

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Process Flow diagram of Textile CETPs

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Brief Summary Performance of Arulpuram CETP

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Stage wise quality detaile

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Conclusion

 ZLD is a Technological Challenge, and the focus must be on Zero Waste

Disposal (ZWD)
 Extensive research and piloting necessary for every single case for
Technology selection and financial viability.
 Brine Concentration, Evaporation and Crystallization and disposal still a
major issue. Focus must be on recovery and reuse of salts.
 Water Scarcity, Water economics and regulatory pressure are the main
drivers of ZLD and will determine financial viability.

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References
 I. Sajid Hussain. “Indian Case Study on ZLD -The Tirupur Textile
cluster experience” 28th January, 2014
http://www.igep.in/live/hrdpmp/hrdpmaster/igep/content/e48745/
e49028/e58765/e58767/CETP_RT_TWIC.pdf

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