UNIT-4 INTRODUCTION TO

INDUSTRIAL WASTE
• Introduction
• Industrial scenario in India - Uses of water by industry
• Sources and types of industrial wastewater
• Reasons for treatment of industrial wastewater
• Regulatory requirements and pollution control boards
• Quality requirements of boiler and cooling waters

Quality requirements of process water for:

a. Textiles
b. Food processing and
c. Brewery Industries
UNIT-4 INTRODUCTION TO
INDUSTRIAL WASTE
Self Study:
• Industrial Water Use and Wastewater Management in the
Textile Industry, Food Processing Industry, Brewery
Industries, Steel Manufacturing plant etc. in India
MAJOR INDUSTRIAL SECTORS IN INDIA
WHAT IS INDUSTRIALIZATION?
Industrialization is a process by which the center of gravity of the economy
shifts from agriculture to industry.

Industrialization involves two things:

i) Adoption of technologically superior techniques of production that help to

transform basic raw materials and intermediate goods into manufactured goods.

ii) Application of modern techniques of management and organization like

economic calculations, accountancy and management techniques, etc.
FACTORS DELAYING INDUSTRIALIZATION IN
DEVELOPING COUNTRIES
INDUSTRIAL DEVELOPMENT IN INDIA

The changes in the structure of industrial growth in India during the last six
decades can be more easily examined and analyzed under two broad heads,
viz.,
i) Dimensions of Industrial Growth, and ii) Pattern of Industrialization.
DIMENSIONS OF INDUSTRIAL GROWTH
INDUSTRIAL WATER DEMAND
USES OF WATER BY INDUSTRIES

1. Process Water – Used in manufacturing, product formulation.

2. Cooling Water – Heat exchange, machinery cooling.

3. Boiler Feed Water – Steam generation, turbines.

4. Cleaning & Washing – Equipment, raw materials, final products.

5. Sanitation & Domestic Use – Restrooms, cafeterias.

6. Waste Disposal & Effluent Transport – Dilution & transport of

industrial waste.
SOURCES OF INDUSTRIAL WASTEWATER
SOURCES OF INDUSTRIAL WASTEWATER

Agricultural Waste: The agricultural sector produces an enormous

volume of wastewater every year.
The two main sources of wastewater in agriculture are:
a) non-point source pollution and
b) point source pollution.

Non point source pollution is generally a result of surface run offs from
fields, especially during periods of excessive rainfall, whereas point
source pollution in agriculture is a localized source constituting animal
waste, treatment, piggery waste, firewater, silage liquor, milking parlor
wastes, slaughtering wastes and vegetable washing wastes.

Run offs in non point source may also include nutrients, pesticides and
soil sediments that cause high levels of turbidity in water bodies,
encouraging the growth of aquatic plants, clog fish gills and smother
SOURCES OF INDUSTRIAL WASTEWATER
Iron & Steel Industry

The iron and steel industry consumes water mainly for cooling, washing,
gas transfer, matter removal, etc. Right from the mining process to the
fabrication of steel, the entire iron and steel manufacturing process
incorporates powerful reduction reactions in blast furnaces.

The water used for cooling is therefore begrimed by chemicals such as

ammonia and cyanide. Contamination of waste streams includes
gasification products such as benzene, naphthalene, cyanide, ammonia,
phenols and cresols, along with a wide array of more composite organic
compounds collectively known as polycyclic aromatic hydrocarbons (PAH).
Even during other stages, e.g., in the final treatment stage where pickling
is done in strong mineral acids for rust removal and preparing the surface
for surface treatments such as galvanization or painting, large amount of
water is generated which is contaminated by acids like hydrochloric acid
SOURCES OF INDUSTRIAL WASTEWATER
Mines & Quarries

Contaminants of mining and quarrying consist mainly of slurries of rock

particles that arise mainly from rainfall washing exposed surfaces
and haul roads. At times, they are also formed during rock washing and
grading processes.

These inert contaminants are abundantly generated during the extraction

and on-site processing of materials such as coal, china clay, slate,
metalliferous and vein materials.

Although the waste generated is normally chemically inert and stable

enough to be easily deposited on the land without pre-treatment, it has to
be noted that some waste may contain high levels of metals that can
have a harmful effect on wildlife and plants.
Oils and hydraulic oils are also common contaminants of mine and quarry
SOURCES OF INDUSTRIAL WASTEWATER
Complex Organic Chemicals Industry

Chemical pollutants include a wide variety of contaminants ranging from

simple inorganic ions to complex organic molecules.
Organic compounds that are dangerous to the environment are all man-
made and have only existed during the last century.

Apart from the organic chemical manufacturing plants, a lot of other

industries also work with complex organic compounds regularly. These
include pesticides, pharmaceuticals, paints and dyes, petro-
chemicals, detergents, plastics, paper pollution, etc.

These industries generally deteriorate the quality of water by

contaminating it with feed-stock materials, by-products, product material
in soluble or particulate form, washing and cleaning agents, solvents and
added value products.
SOURCES OF INDUSTRIAL WASTEWATER
Nuclear Industry

One of the most water-intensive sectors, the nuclear industry requires

large amounts of water every day, mainly for cooling purposes.

The hot-water outflows, contaminated with radioactive chemicals after

being used in various processes is pumped back to rivers, lakes and
oceans, which poses serious environmental threats. The production of
these radio active contaminants in nuclear-power plants mainly takes
place during the mining and refining stage of uranium and thorium and
the fission reaction involved in the production process. In nuclear fuel
cycle, the front end usually produces alpha-emitting waste from the
extraction of uranium. It often contains radium and its decay products.
The back end, mostly spent fuel rods, contains fission products that emit
beta and gamma radiation, and actinides that emit alpha particles, such
as uranium-234, neptunium-237, plutonium-238 and americium-241, and
SOURCES OF INDUSTRIAL WASTEWATER
Food Industry

Wastewater generated in the food industry though biodegradable and

nontoxic, contains high concentrations of biochemical oxygen demand
(BOD) and suspended solids (SS).

Typically, vegetable washing and animal slaughter and processing

generates waste water that is packed with high loads of particulate matter
(PM) and dissolved organics.

Animal slaughter and processing also lead to the production of strong

organic waste, which are derived from body fluids, including gut contents
and blood. This wastewater also contains pollutants like antibiotics,
growth hormones, and at times pesticides, which come from the animal
body. Even, food processing and cooking generates large to trace amounts
of salt, flavorings, coloring material, acids, alkali, oil or fats.
TYPES OF INDUSTRIAL WASTEWATER
REASONS FOR TREATMENT OF INDUSTRIAL
WASTEWATER
India generates nearly 6.2 million cu.m. of
Industrial wastewater everyday requires treatment
before discharge to meet environmental norms.

Fig. India’s sources of water for Industry Fig. India’s mega cities: domestic and
Industrial wastewater, generated vs
treated
MAJOR POLLUTING INDUSTRIES & NATURE OF
POLLUTANTS
MAJOR POLLUTING INDUSTRIES & NATURE OF
POLLUTANTS
MAJOR POLLUTING INDUSTRIES & NATURE OF
POLLUTANTS
REGULATORY REQUIREMENTS AND POLLUTION
CONTROL BOARDS FOR INDUSTRIAL WASTEWATER

[Link]
HIERARCHICAL APPROACH FOR SOLVING
POLLUTION PROBLEMS
WHAT IS AN ETP?
ETP(Effluent Treatment Plant) is a process design for treating the industrial
waste water for its reuse or safe disposal to the environment.
•Influent: Untreated industrial waste water.
•Effluent: Treated industrial waste water.
•Sludge: Solid part separated from waste water by ETP.
NEED OF ETP
• To clean industry effluent and recycle it for further use.
• To reduce the usage of fresh/potable water in Industries.
• To cut expenditure on water procurement.
• To meet the Standards for emission or discharge of environmental
pollutants from various Industries set by the Government and avoid
hefty penalties.
• To safeguard environment against pollution and contribute in
sustainable development.
DESIGN OF ETP
TREATMENT LEVELS & MECHANISMS OF ETP
PRELIMINARY TREATMENT LEVEL
PRIMARY TREATMENT LEVEL
PRIMARY TREATMENT LEVEL
SECONDARY TREATMENT LEVEL
TERTIARY / ADVANCED TREATMENT
FLOW CHART FOR ETP
 POSSIBLE CHOICE FOR
WASTEWATER TREATMENT AND THEIR
SEQUENCE
FLOWCHART OF ETP
• CETP (Common Effluent Treatment Plant) :
• Common effluent treatment plants (CETPs) are treatment systems specifically designed for
collective treatment of effluent generated from small-scale industrial facilities in an industrial
cluster.

Operational layout
of CETP
• CETP (Common Effluent Treatment Plant) :

• [Link]

• Effluent Treatment Plant

• [Link]
• Factors in selection of unit operations and processes
• The various method used in industrial wastewater treatment are identical to those used in treating
domestic sewage.
• The factors considered for selection depends upon:
1. Very high degree of variability in the quantity of industrial wastes compared to domestic sewage.
2. Large variations in flow rates of industrial waste
3. Presence of hazardous and toxic pollutants in some industrial wastes.
• Unit Operations : Removes contaminants by physical forces.
• Example : Screening, sedimentation, flotation, filtration, mixing, equalization, osmosis, drying,
incineration, adsorption etc.
• Unit Processes: Removes contaminants by biological or chemical reactions/forces.
• Example: pH correction, coagulation, oxidation, reduction, disinfection, aerobic, anaerobic biological
treatment.
• Sequencing of Unit Operations :
• Screening
• The Screens are devices with clear openings of uniform space used to remove floating materials & coarse
solids from wastewater.
• Mainly floating materials like plastics, pieces of wood, rags are removed by screening.
• Screens are provided to protect: Pumps, Valves, Pipe line and other appurtenances from damage or
clogging by rags and other large objects.
• Classification of screens:
1. According to method of cleaning : Hand Cleaned & Mechanically cleaned
2. According to size of clear opening - Coarse , Medium, Fine Screen depending upon size of opening
between the bars,
• Coarse Screen : More than 50 mm
• Medium Screen : 25-50 mm
• Fine Screen : 10-25 mm
• Sequencing of Unit Operations :
• Screening
• [Link]
 SCREENING
⮚Screening is the filtration process for the separation of coarse particles from influent.

⮚ Stainless steel net with varying pore size can be utilized.

⮚ Screens are cleaned regularly to avoid clogging.

• Sequencing of Unit Operations :
• Flow Equalization

• Equalization tank is to act as a buffer, to collect the raw incoming influent that

comes at widely fluctuating rates and pass it on to the rest of the treatment plant

at a steady flow rate.

• It is used to overcome the operational problem and equalize the strength of

influent water which provide a uniform flow, this tank are employed after screen

and grit chambers .

• The capacity of an equalization basin is computed based on its location i.e.

whether the tank is provided “in line” or “off the line” of flow .
• Sequencing of Unit Operations :
• Flow Equalization

A : In-line location of Equalization basin

B : Off-line location of Equalization basin

• Sequencing of Unit Operations :
• Flow Equalization
• Plot for computation of volume of an equalization basin.
 EQUALIZATION TANK
⮚ Equalization makes the waste water homogenous.

⮚ Retention time depends upon the capacity of treatment

plant. (Generally 8-16 hours)

Spray of water coming

from dyeing unit

Cool
Influent from &
screening Homogenous
EQUALIZATION TANK influent to
pHcorrection
Tank

Air for diffusion

• Sequencing of Unit Operations :
• Mixing Process
• It is one of the important unit operation process and used for mixing of one
substances with another.
• Continuous rapid mixing is achieved by providing baffles, by fixing static mixers
or venture flumes in pipelines.
• Mixing process helps in giving partial treatment to waste water streams of
opposite nature, for example : neutralization of acidic and alkaline effluents.
• The mixing process may also be accomplished by the process of aeration, because
the compressed air causes the circulation of the waste water. In addition, this
process provides more available oxygen for life processes of organisms, which
degrade the organic compounds contained in the wastewater.
• Air nozzles may also be used. Compressed gas is introduced to the lower part of
the chamber, its center or to its perimeter. This results in the effective mixing of
the sludge without fragmentation of fibers
• Sequencing of Unit Operations :
• Mixing Process
• [Link]
• [Link]

• Types of Mixers
1. Static Mixer
• A static mixer consists basically of a sequence of stationary guide plates which
result in the systematic, radial mixing of media flowing through the pipe.
• The flow path follows a geometrical pattern, precluding any random mixing.
• The mixing operation is therefore completed within a very short flow distance.
• The formation of fine gas bubbles in a water/gas mixture promotes intensive
contact between the two phases.
• The result is high mass transfer, for instance a high oxygen transfer rate, static
mixers ensure that the complete fluid stream is subjected to compulsory or
enforced mixing or contacting.
• Sequencing of Unit Operations :
• Principle of Static Mixing
• In case of two miscible liquids in laminar flow, the main mechanism in a static
mixer is flow division.
• The elements are helical or pseudo-helical and are arranged in a series of
alternating left and right hand 180 twists.
• The elements split the fluids entering in two streams and than rotate them
through 180 degrees. The elements are in series in the mixer. As the number of
streams or layers increases, the layer thickness decreases.
• In case of two miscible liquids in a turbulent flow, the main mechanism is radial
mixing: fluids are constantly moved from the pipe center to the pipe walls and the
fluid change direction with each succeeding element.
• To achieve a fully homogeneous mix in a turbulent flow 1.5 to 4 elements are
sufficient.
• Sequencing of Unit Operations :
• Principle of Static Mixing
• [Link]
• [Link]
• The main applications are in the following fields:
• Water and wastewater treatment:
• Coagulation processes, e.g. for phosphorous removal from waste water
• Chemical dosing & Representative sampling
• Aeration of drinking water
• PH control
• Disinfection of drinking water, e.g. chlorination and de-chlorination
• Diluting flocculants and mixing with water, wastewater or sludge
• Ozone injection and mixing
• Desalination of seawater Reverse Osmosis Systems
• Sequencing of Unit Operations :
• Mechanical Mixing
• Mechanical mixers are widely used for rapid mixing because of their good control
features.
• They are usually placed in a small chamber or tank and include the propeller,
impeller, or turbine types.
• The detention time in these chambers is designed to be very short.
• Mechanical mixers can also be mounted directly into a pipeline; they are then
referred to as in-line-mixers.
• The type of unit provides good instantaneous mixing with little short circuiting,
costs much less than a conventional rapid-mixing installation , and still allows for
adjustment to provide the correct amount of mixing energy.
• All in-line mixers must be located close to the flocculation chamber so that
flocculation and settling will not occur within the pipeline.
• [Link]
• Sequencing of Unit Operations :
• Sedimentation and Flotation
• It is a simple settling tank, normally rectangular or circular in shape.
• Removal of finely suspended and settle able solids is done by plain sedimentation,
while chemically aided sedimentation is required for removal of colloidal solids.
• Flotation is a unit operation which is used for the removal of lighter suspended
solids, oil, grease.
• The separation of particles takes place near the top of tank, at the surface level of
liquid, this is exactly opposite to that of gravity sedimentation where particles are
removed at the bottom of tank.
• Flotation is particularly useful in woolen mills, slaughter houses, pulp and paper
mills , oil refineries and dairies.
• Both of these methods i.e. sedimentation and flotation help reduce the solids load
on treatment units and also help in recovery of useful material from wastewater.
• Sequencing of Unit Operations :
• Function of Sedimentation Tank
• PST as a treatment unit
• Load Reducing unit
• PST as settling unit for primary treatment and ASP
• Role as holding tank to reduce organic suspended solids
 SEDIMENTATION TANK

⮚In this tank sludge is

settled down.

⮚Effluent is discharged from

plant through a fish pond.

⮚ Sludge is passed to the

sludge thickening unit.
 SCHEMTIC DIAGRAM OF SEDIMENTATION TANK

Waste water from

sedimentation pack
Sludge to
thickening unit
SEDIMENTATION
TANK

Effluent

Effluent
Discharge
Fish pond

Fish Pond is used to see survival of fishes to ascertain fitness of water for disposal
• Sequencing of Unit Processes :
• pH correction
• A pH Correction Tank is a tank is designed to store water for long enough for the
water to be treated with acid or alkaline so that neutralized effluent can be
returned to drain.
• pH Correction Tanks are generally fitted with a top-mounted mixer to improves
the efficiency and speed.
• These incoming and outgoing flows in the pH neutralization system are generally
controlled by pumps activated by level controllers and low-level floats switches.
• This treatment requires adequate mixing between the waste stream and
neutralizing chemical.
• Chemicals used are sulphuric acid, hydrochloric acid, nitric acid, phosphorus acid,
lime, sodium hydroxide, sodium carbonate, ammonium hydroxide.
• Sequencing of Unit Processes :
• pH correction
• A pH Acidic water results in the corrosion of pipework and heating
cylinders or equipment and iron/manganese present will result in poor tasting
water in addition to staining baths, basins, and any appliances with which the
water may come into contact.
• pH in Wastewater Treatment
• It has a direct influence on wastewater treatability whether treatment is
physical, chemical, or biological.
• The pH of the effluent water affects the separation of other pollutants from the
water where treatment plants are removing suspended solids from water.
• pH controllers are used to correcting pH levels to the desired range to enable
coagulants (chemicals that clump together small particle solids) to operate
efficiently and bring particle solids in suspension together to enable efficient
removal from water
 PH CORRECTION

⮚ In this tank pH of the influent is corrected to meet the standard.

⮚Acid or alkali is added to the effluent to increase or decrease the pH.

Acid or alkali

Influent from
equalization
tank pHcorrection Influent of desired
to pH disperse unit
 DISPERSE UNIT
Disperse tank mixes the sludge coming from recycle tank with
waste water for to proper aeration.

Sludge from
recycle tank

Influent from pH DISPERSE UNIT

Mixed
correction tank ( MIXING OF SLUDGE & WASTE) influent &
sludge to
aeration
• Sequencing of Unit Processes :
• Coagulation
• Chemical treatment typically is applied prior to sedimentation to enhance the ability of a treatment
process to remove particles.
• Two steps typically are employed: coagulation and flocculation.
• Coagulation is a process to neutralize charges and then to form a gelatinous mass to trap (or bridge)
particles thus forming a mass large enough to settle or be trapped in the filter.
• Flocculation is gentle stirring or agitation to encourage the particles thus formed to agglomerate into
masses large enough to settle or be filtered from solution.
• Coagulation is the chemical water treatment process used to remove solids from water, by manipulating
electrostatic charges of particles suspended in water.
• The purpose of adding a coagulant is to neutralize the charge.
• In theory, since most particles in water are negatively charged, any positive ion (cation) can be used as a
coagulant.
• Sequencing of Unit Processes :
• Coagulation
• Chemical commonly used for this purpose are alum, ferric chloride, ferrous
sulphate, ferric sulphate, lime etc.
 AERATION

⮚Function of aeration is
oxidation by blowing air.

⮚Aerobic bacteria is used to

stabilize and remove organic
material presents in waste.
 SCHEMTIC DIAGRAM OF AERATION

Aerobic bacteria

Mixture of Discharge to
AERATION TANK
waste water sedimentation
& sludge tank

O2

AIR
REACTION IN AERATION TANK:
BAC
ORGANIC MATTER + O2 TERI CO2+ HO2 +
ANUTRIENT HEAT
EFFLUENT DISCHARGE
 SLUDGE THICKENING UNIT

⮚Here sludge is dried and

discharged.

⮚Partial amount of sludge is

returned back to the aeration tank
from thickening unit through
recycle tank called return sludge
tank and disperse tank.
 SCHEMTIC DIAGRAM OF SLUDGE
THICKENING UNIT

Sludge from Sludge discharge

sedimentation unit

SLUDGFE
THICKENING UNIT

Sludge to recycle
tank
DRIED SLUDGE
 RETURN SLUDGE TANK

Function of return tank or recycle tank is to mix water with sludge

This mixture is then passed to aeration tank through disperse tank.

ADVANTAGE OF RECYCLE SLUDGE TO AERATION TANK

⮚ Sludge again oxidized to minimize the pollution from sludge.

⮚Alive bacteria of sludge is again used in aeration to utilize this bacteria.

Sludge from
Sludge to aeration
thickening
SLUDGE tank through
unit
RECYCLE TANK disperse unit

Mixing of sludge &

water
 PERMISSIBLE STANDARDS IN INDIA
[Link]. Parameter Permissible limits
(disposal to inland
surface water)
1 pH 5.5 to 9.0
2 TSS <100 mg/l
3 Oil & Grease <10 mg/l
4 BOD <30 mg/l
5 COD <250 mg/l

[Link]
WATER REQUIREMENT OF POWER PLANTS
Boiler feed water is deionised water used to absorb the
chemical energy of fuel to heat energy.

Since the boiler water is in circulation and significant loss

occurs in the form of evaporation and blow down, only
make up water is required. The quantum of blow down
water depends on boiler steam parameters and make up
DM water.

The quantity of boiler feed blow down can be calculated

using the formula B = E x S/ C-S m3/h where B is quantity
of blow down in m3/h, S & C are TDS of feed water and
boiler drum
WATER REQUIREMENT OF POWER PLANTS
Around 80% of water consumption in power plants are
taking place in the cooling system.

For a typical 500 MW coal fired unit, the amount cooling

water required is 60,000 m3/h, with temperature rise
across the condenser about 9.5oC.

Generally in case of closed cooing cycle system, water loss

results in evaporation of 1.5-1.7 % of cooling water flow for
heat removal and drift loss amounts to typically 0.05% and
0.35% blow down of the cooling water flow
WATER QUALITY REQUIREMENT
DM water is used as make up in boiler and its characteristics properties
well below the value presented. The specific parameters such as pH (7.5 –
9.6), conductivity ( 1 μS/cm), dissolved oxygen (0.04 mg/l), alkalinity
(carbonate free), hardness (0.3 mg/l), silica ( 0.5 mg/l) and Oil and grease
(free) are desirable for boiler feed water.

The cooling circulation water should not exceed the corrosion and heat
exchange influencing parameters such as pH (6.2-8.2), conductivity (80
μS/cm), chloride (200 mg/l), sulphate (200 mg/l), methyl orange alkalinity
(100 mg/l), total hardness 9 200 mg/l), Fe ( 1 mg/l), Cu (0.3 mg/l),
ammonia (0.1 mg/l), residual chlorine (0.3 mg/l) and sulphide ( free).

Domestic water has to meet the prescribed standard

EFFECTS OF WATER QUALITY
EFFECTS OF WATER QUALITY
EFFLUENT STANDARDS