Case study - Textile ETP [Spinners & Spinners]

Textile Color Waste Water

Ozone Oxidation in

Primary Stage

Spinners & spinners – Kenya - Textile color effluent Case Study

INDEX 1. Site Data 2. Present Scenario 3. Objective 4. Offered Solution & Technology 5. General Arrangement Drawing & PFD 6. Implementation – Site Pictures & Video 7. Operation & Maintenance 8. Consumables & Replacements 9. Savings 10. Return On Investment [ROI]

Site Data :

Site Location : Nairobi - Kenya

ETP Capacity : 100 KLD

Present Treatment : Physico-Chemical Process

Present Process Scheme : Equalization + Chemical Dosing +

Coagulation + Flocculation + Clarifiers

+ Sand Filter + Carbon Filter

Present Scenario :Color effluent from textile plant :

Raw color waste water is collected in equalization tank from different

areas. High quantity of chemicals are used to treat this color effluent

to make it colorless & then recycled back in process. Due to addition

of chemicals TDS of water goes on increasing & due to this blow

down water quantity is high. Also due to use of chemicals, operating

cost & cost of recycled water is high.

Objective :

Enhance Recycled quality of water

Reduce Chemical Consumption to reduce Operating cost.

Implement Environmental Friendly Technology

Higher degree of Compliance

Offered Solution & Technology :Ozonation in equalization tank – Primary stage

Ozone is a very strong oxidizing agent.

Ozone react much faster than any other oxidizer.

Ozone can efficiently break complex molecular bond.

Ozone enhances coagulation & flocculation.

Crucial part of the solution is to integrate ozone in existing scheme with optimum ozone dose.

Process Flow

Diagram

G. A.Drawing

Implementation :Ozone

Generator Plant Room

Raw Effluent Collection Cum

Equalization Tank 3

Raw Effluent Collection Cum

Equalization Tank 1

Raw Effluent Collection Cum

Equalization Tank 2

Implementation : Ozonation Plant RoomCooling Tower for Ozone Cell

Cooling

Water Cooled Ozone Generator

150 G/hr

For Safety Back Flow Preventer

Oxygen Concentrators

Implementation : Flow Direction

Submersible Pump

Ozone Connecting

Flexible Tubing

Ventury Injection

Waste Water

Flow From 3rd

Equalization

Tank to 1st, via

Ventury, where

Ozone in Dossed

Implementation : Ozone Mixing in Circulation Mode

Effect Of Ozone Can be

seen in first tank, where

complex molecular bonds

of Organic & Reactive dies

are broken into simpler

chemical bonds.

Savings & Returns On Investments [ROI] :Chemicals Chemical

Specification

Quantity Per Day Rate Per Unit

Cost Per Day SavingsBefore

OzonationAfter

OzonationBefore

OzonationAfter

Ozonation

  Name Kg or Ltrs Kg or Ltrs KS KS KS KS Chlorine   45 25 180 8,100 4,500 3,600

Ph Adjust NaOH 10 10 70 700 700 -

Coagulant   25 - 90 2,250 - 2,250

Flocculent   0.4 0.4 716 286 286 - Total CostPer Day         11,336 5,486 5,850

Total CostPer Year         4,137,786 2,002,536 2,135,250

Savings inUSD per Yr         45,975 22,250 $ 23,725

Ozonation Project Cost in USD [Including Supply + Wooden Packing + Air Freight + I & C] $ 35,000

Return On Investment [In Years] KS – Kenya Shilling 1.48

Savings :

Ph Correction Chemical : 0 %

Chlorine : 44 %

Coagulant : 100 %

Flocculent : 0 %

Benefits : Reduction In Chemical Cost – Reduction in OPEX

Less Storage, Transport & Handling – Space & Time saving

Higher Quality of Treated Waste Water

Lower Operational Time – [Higher Plant Capacity]

Higher Recovery – Less Blow Down [Lower Waste Water TDS]

Lower Sludge Formation & Handling

Return On Investment:

Savings Per Year : $ 23,725

Total Capital Cost : $ 35,000

Return On Investment : 1.47

ROI : 18 months

Operation & Maintenance : Ozonator is fully electrical operated. [No Consumables]

Ozonator should be operated 24 x 7

Routine maintenance frequency is once in months

Break-down repair/maintenance will be attained in 48 hrs.

(Depending on site criticality & reliability of equipment, standby

units are recommended)

Consumables & replacements : Consumables : Electricity Power - 4.5 Kwatt

Electrical consumption : 2.0 kw x 24 hrs = 48 kw-hr

Replacements:

Ozone cell : 2 – 2 ½ yrs : $ 1,000

No. of Ozone Cells : 02 nos.

Molecular sieves : 1 ½ - 2 yrs : $ 400

No. of Sets (Mol. Sieves) : 04 nos.

Thanks For your Precious time

For more Information :

Visit : www.chemtronicsindia.com / www.ozonegeneratorindia.com

Email: sales@chemtronicsindia.com

Call / Whatsapp : Mr. Sunil Shah - +91-9321234527

Skype : sunilshah.chemtronics