MATEC Web of Conferences 152, 02005 (2018)

https://doi.org/10.1051/matecconf/201815202005
Eureca 2017

Design and Optimisation of Home Scale Greywater

Recycling Package
Kalaichelvan a/l Arugam1, Azadeh Ghadimi1,*, and LH Chang 2
1
Department of Mechanical Engineering, Taylor’s University, Malaysia
2
DD Techniche Sdn. Bhd., No. 11-3, Jalan USJ 21/1, UEP Subang Jaya, Selangor, 47630
Subang Jaya, Malaysia

Abstract. Water crisis is becoming one of the biggest challenges in

some countries due to over population and drought. Therefore,
government and non-government organisations in well-developed
countries are encouraging industries to install water recycling
package to reduce water usage and consume greywater instead.
However the home scale is not yet available in the market. This
research focuses on design a home scale greywater treatment
system for toilet flushing within 3,000 to 5,000 USD as a
collaboration with DD Techniche Sdn Bhd. Greywater is the waste
water produced from laundry, kitchen and bathroom except the toilet
waste and contains suspended solids, microorganisms, oil, nitrates
and phosphorus which needs to be treated using suitable types of
treatment for safe reuse. The treatments include physical, chemical
and biological water treatment in which in this study the proposed
system is a combination of all three. The design is evaluated using
experimental methods to meet the standard of toilet flushing quality.
The greywater system consists of the mechanical parts to control
the flow of greywater and store the treated water including pumps,
sand filtration tank, wire mesh chassis and collection tank. The final
design has dimension of 6 m3 and optimised price within the
budget.

1. Introduction
Water crisis is becoming one of the biggest threat in some countries. Especially, countries
in Middle East are facing severe water crisis due to drought. Countries with high population
also face water crisis due to high water usage [1]. Water crisis can be reduced by
controlling the water usage. One of the successful method to control water usage is by
recycling rain water and greywater. Government and non-government organisations are
encouraging industries to have water recycling system to reduce water crisis. DD Techniche
Sdn Bhd is a water recycling package Installer Company has seen the potential to market a
home scale greywater treatment for toilet flushing within the budget ranging between 3,000
USD to 5,000 USD.

1
Corresponding author: [email protected]

© The Authors, published by EDP Sciences. This is an open access article distributed under the terms of the Creative Commons
Attribution License 4.0 (http://creativecommons.org/licenses/by/4.0/).
MATEC Web of Conferences 152, 02005 (2018) https://doi.org/10.1051/matecconf/201815202005
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The company has come out with this initiative due the attention gained by the industrial
scale greywater treatment package and the absence of home scale greywater treatment
system. Greywater is the water produced from the laundry, kitchen and toilet except the
toilet wastes [2]. Greywater contains phosphorus and nitrates due to the usage of detergent,
shampoo and dishwasher liquid [3]. Greywater also contains bacteria, total suspended
solids, oil and grease. The total suspended solids (TSS) are hair from the bathroom, dirt
from laundry and food particles from kitchen. These contents in the greywater causes
infection to the user if not treated. Therefore, the greywater must be treated before reusing
it for toilet flushing.
There are three types of treatment, which are the physical treatment, chemical treatment
and biological treatment. Physical treatment involves filtering out particles from water
based on the size using wire mesh or membrane [4]. This treatment is applicable to filter the
suspended solid and reduce the turbidity. Chemical treatment is process of adding
chemicals into the water to neutralise the bacteria through salt addition [5]. Chemical
treatment also involves coagulation process. Coagulation is the process of accumulating the
bacteria together to increase the size and filter out using the physical treatment [2].
Biological treatment is microbial reaction using microorganism to convert bacteria into gas,
water and biomass [6].
Greywater treatment must consist at least two types of treatment because chemical or
biological treatment can treat bacteria but need to be supported by the physical treatment to
filter the solid particles. The design of greywater treatment package for this project requires
to have dimension of 2 m x 2 m x 2 m and budget within 3,000 USD and 5,000 USD. The
design for this project is be inspired from the existing industrial scale water recycling
system. The existing industrial designs for greywater recycling system are slow sand
filtration, membrane bioreactor and water treatment with clarifiers.
The final design of greywater treatment package for this project is made up of pre-
treatment stage with wire mesh and followed by slow sand filtration. This design consists
all three types of water treatment stated above. The pre-treatment with wire mesh involves
physical treatment to filter out food particles, hair and other suspended solids. The slow
sand filtration involves physical treatment, biological treatment and chemical treatment.
The water is accumulated at the top of sand to form platform for biological treatment. Then,
the water passes through the sand and the waste from the biological treatment is filtered out
by the sand layer. The nitrates in the water are be treated through denitrification by the sand
layer.
The greywater treatment package consists of mechanical parts to control the flow and
store the greywater for toilet flushing. The mechanical parts are pumps, sand filtration tank,
wire mesh chassis and collection tank. The mechanical parts are designed based on the flow
rate of the greywater. The pumps are used to pump the water from the collection tank to
storage tank at the roof top for distribution. The sand filtration tank is designed based on the
flow rate entering the sand filtration and requirement of sand height by the environmental
organisations. Wire mesh are designed based on the size of particles to be filtered out and
budget.
The design is evaluated by comparing the treated water with standard water quality for
toilet flushing. The system must be able to meet the water quality for toilet flushing. The
water quality is compared by measuring the total suspended solid (TSS), chemical oxygen
demand (COD) and turbidity. These three parameters must meet the standard water quality
for toilet flushing. The final design is represented in 3D model with all the mechanical parts.
The objectives of this project are to design a home scale greywater recycling package
and optimise the design by having low cost compare to existing designs in the market. The
final design is able to treat the greywater for toilet flushing. The design is optimised by
having lower cost than existing home scale greywater package.

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This project creates the chance for the public to use the greywater treatment system for
household. These reduces the water usage for the public, which will reduce the cost if the
system is used for long term. Reducing water usage results in reduction of water crisis. This
system able to gradually bring advantage to the economy and environment. Since, public
are not using any water recycling system currently because water recycling systems are
only manufactured in industrial scale, this project able to fulfil the gap of designing a home
scale water recycling system.

2. Methodology
This project involves designing, 3D modelling, prototyping and experimental evaluation.
The designing involves the designing of pre-treatment stage with wire mesh, slow sand
filtration and pump. The design is modelled into 3D prototype using SolidWorks Ver. 2016.
The performance of the design is evaluated using the prototype.

2.1 Designing Stage

The greywater treatment system consists of pre-treatment filter, slow sand filtration, pump,
and collection tank. The greywater enters to the pre-treatment filter and follow by the slow
sand filtration. The treated water is collected in the collection tank. Then, the treated water
is pumped to the storage tank using the auto water pump. The treated water is distributed to
the toilets from storage tank.
The pre-treatment filter consists coarse and fine wire mesh. The pore size of coarse wire
mesh is 1 mm and the pore size for the fine wire mesh is 0.5 mm. The coarse mesh is used
to filter out hairs and particles that are larger than 1 mm. The fine mesh is used to filter out
dirt and particles larger than 0.5 mm. The pre-treatment stage is designed vertically to use
the gravitational force during the filtration. The gravitational force provides extra support to
push the water through the pores of the wire mesh. The wire mesh is designed to have
hemispherical surface to provide larger filtration area. The hemispherical shape also
provides the slippery slope for the movement of filtered particles through the drainage pipe.
The slow sand filtration consists sand layer and gravel. The slow water flows on the
sand causes the water to accumulate at the top to form water bed for the biological
treatment [7]. The biological treatment transforms bacteria into gas, water and biomass. The
biomass is filtered by the pores between the sand. The sand also involves chemical
treatment. The sand neutralises the nitrates through denitrifications [8].
The slow sand filtration is designed based on the volumetric flow rate equations and
requirement by the environmental organisation [8]. Volumetric flow rate equation is
applied to calculate the filtration area of the sand. Volumetric flow rate means the volume
of water passes through medium per unit time. The volumetric flow rate equation is shown
below.
𝑄𝑄
A= (1)
𝑣𝑣

Where, A = surface area of the sand filter (m2)

Q = flow rate onto the filter surface (L/h)
v = loading rate of sand (L/hm2)
The flow rate of greywater in household are obtained from the journal published by the
Texas A&M University from United States [9]. The data are shown in Table 2. The loading
rate is set at 400 L/hm2 because it is the optimum loading rate for sand filtration based on
the environmental organisations from United States and United Kingdom. Therefore, the
surface area of the sand filter can be calculated by substituting the parameters.

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The height of sand filtration and gravel are designed based on the standard dimension
set by the environmental organisation from well-developed country. This dimensions are
set by the organisations based on the feedbacks gathered from the existing slow sand
filtration. The dimensions are listed in Table 3.

Table 1. Parameters for sand filtrations system [7,10]

Organisations Parameters Dimensions

Sand depth ≥50 cm
Cisco Foundations Loading rate 400 L/hm2
Gravel Depth ≥5 cm
American Water Works Association Sand Depth ≥50 cm
Loading rate 100 L/hm2-400 L/hm2
Based on requirement in Table 1, the height of sand is set to 50 cm and the height is
validated by applying Darcy’s law. Darcy’s law is used to calculate the flow rate of liquid
that passes through a porous medium. Darcy’s law states that the water flows from high
potential area to low potential area. Therefore, the water in the sand filter obeys this law
where, the water on top flows to the bottom due to the potential difference. Darcy’s
equation (2) is given as shown below. The sand depth recommended by environmental
body is validated using the Darcy’s law.
ℎ+𝑑𝑑
Qmax=k.A. (2)
𝑑𝑑
Where, Qmax= Maximum flow rate (m3/s)
k= Hydraulic conductivity of sand (m/s)
h= Depth of clearance above the sand (m)
d=Depth of sand (m)
The designing of pump includes the process of transferring the water from collection
tank at the slow sand filtration to the storage tank. Auto water pump is used in this project
because the slow sand filtration required longer time to fill in the collection tank. The pump
should operate once the collection tank is full. Auto water pump activates based on the
water level. Therefore, auto water pump is the ideal choice for this project.
The suitable pump can be chosen based on the water horsepower. The parameters that
are related in the horsepower pump designing is the head loss and water flow rate. The
equation relating these parameters are shown below. Head loss is the distance to pump the
water from one point to another point. The pump for this project must be able to transfer the
water from the collection tank to storage tank at the rooftop. Therefore, the head loss is the
height of the house, which is generally 5.7 m.
𝑄𝑄×𝐻𝐻
WHP= (3)
3960
Where, WHP= Water horsepower (hp)
Q= flow rate of water from the pump (gallon/minute)
H= head loss or distance to pump the water (foot)

2.2 3D Modelling

The design of the pre-treatment stage and slow sand filtration are modelled as software
prototype using SolidWorks Ver. 2017. The pre-treatment stage consists of three parts,
which are the mesh holder, filtration chassis and chassis connector. The mesh holder is
placed in the filtration chassis and the coarse filtration chassis is connected to the fine
filtration chassis using the chassis connector. Since, 4 inches PVC pipe commonly used as

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greywater outlet, the pre-treatment stage is designed to have same dimension as 4 inches
PVC pipe for ease of installation. The drawing of mesh holder is shown in Figure 1.

Fig. 1. Mesh holder

The slow sand filtration chassis was designed based on the calculations carried out
using the equations and requirements as discussed in Section 2.1. The slow sand filtration
consists two parts which are the chassis and connector. The chassis is used to fill the sand
and gravel. The connecter is used to connect the sand filtration to the pre-treatment stage.
The complete 3D model is shown in Figure 2.

Coarse filtration

Fine filtration

Slow sand filtration

Fig. 2. Drawing of the whole filtration system

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2.3 Prototyping
The prototyping stage involves the manufacturing of the pre-treatment filter and the sand
filtration to evaluate the design. The pre-treatment filter is built using the 110 mm PVC
pipe with PVC pipe connector. The wire mesh for fine screening and coarse screening are
glued in the pipe using adhesive bonding. The complete prototype model for pre-treatment
filter is shown Figure 3.

Coarse screening

Fine screening

Fig. 3. Pre-treatment filter

The slow sand filtration is manufactured using plastic tanks. The slow sand filtration is
manufactured in scaled down dimension because the prototype is only needed to evaluate
whether the system can treat the greywater to meet standard quality of water for toilet
flushing. The prototypes are manufactured for use of experiments to evaluate the design.

2.4 Experiments
The project involves the experiments to measure the flow rate entering the sand filter from
the pre-treatment stage, total suspended solid (TSS), chemical oxygen demand (COD) and
turbidity. The TSS, COD and turbidity is measured to evaluate whether the treated water
meets the standard water quality for toilet flushing. The standard water quality for toilet
flushing is gathered from various water quality department as shown in Table 2. The
performance of the design is evaluated by comparing the treated water with parameters in
Table 2.

Table 2. Water quality for toilet flushing based on American standards

Organisation Parameter Value

BOD ≤10 mg/L
United States Environmental COD -
Protection Agency (US EPA) [11] Turbidity ≤ 2 NTU
TSS -

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BOD ≤10 mg/L

World Health Organization [12] COD -
Turbidity -
TSS ≤10 mg/L
BOD ≤10 mg/L
COD -
Canada Health Department [13]
Turbidity ≤ 2 NTU
TSS ≤10 mg/L
BOD -
The International Water Quality COD ≤30 mg/L
published book titled Milestone in
Turbidity -
Water Reuse [14]
TSS -

2.4.1 Flow Rate Test

The objective of this experiment is to determine the flow out rate of the greywater from the
pre-treatment stage. Flow out rate is needed to calculate the surface area for the slow sand
filtration. The experiment is conducted to obtain the relationship between the flow in and
flow out of the pre-treatment system. The relationship can be used to approximately
measure the flow out rate at any particular flow in rate for the pre-treatment stage.
The experiment is conducted by measuring the flow in rate from tap water by adjusting
the tap at different angle. The time taken to fill 2 L of water at each angle is recorded. The
procedures are repeated by passing the tap water through the pre-treatment filter. The time
taken to fill 2 L of water with the presence of pre-treatment filter represents the flow out
rate and the time taken to fill 2 L of water with the absence of pre-treatment filter represents
the flow in rate. The graph of flow out rate against flow in rate is plotted and the
relationship is obtained. Based on the relationship, the flow out rate is substituted into
equation 1 to calculate the surface area for sand filtration.

2.4.2 Turbidity Experiment

The turbidity of the treated water is measured using the turbidity tube. Turbidity tube is
measuring cylinder with a reference disk at the bottom of the tube as an indicator. The
treated water is filled up until the maximum level, where the reference plane is still visible
as shown in Figure 4. Then, the height of the water level in the cylinder is measured. The
height is converted into turbidity scale using the table obtained from lab manual prepared
by Chicago River Schools Network [15].

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Fig. 4. Filling the treated water until the maximum level, where the disk is visible

2.4.3 Chemical Oxygen Demand Experiment

Chemical oxygen demand, COD is the total oxygen consumption by all the organic
substances in the water [16]. High values of COD indicate the water has high level of
microorganisms and pollution [17]. The COD experiments is carried out by adding nitric
acid into the treated water. Then, the mixture is heated until the oxidation process
completed and the remaining unreacted nitric acid is weighed. The mass of reacted nitric
acid is calculated by subtracting the remaining unreacted nitric acid added to the treated
water. The mass of dissolved nitric acid represents the COD of the treated water in g/L.

2.4.4 Total Suspended Solid Experiment

Total suspended solid (TSS) is the quantity of solid particles in the water. The TSS
experiment involves the evaporation of the treated water. 1 L of treated water is evaporated
under the sun and leftover residue after evaporation is weighed. The mass of leftover
residue represents the TSS value in g/L.

2.5 Limitation
Limitation in this project is the usage of instruments for the measurement of COD, TSS and
turbidity of the water. The COD, TSS and turbidity of the water are measured using manual
experimental method. The instruments are not used because budgets or facility to borrow
the instruments are not allocated by the industry supervisor. Therefore, the manual methods
of determining this parameter involve limitation such as the scale and sensitivity. The
turbidity test only able to give minimum value of 5 NTU.

3. Results and Discussion

The data of time taken to fill 2 L of water with the absence of pre-treatment filter is
tabulated as shown in Table 3. Table 3 shows the flow in rate when the tap is at different
angle. Table 4 represents the time taken to fill 2 L of water with the presence of pre-
treatment filter. The graph of flow out rate against flow in rate is plotted as shown in Figure
7.

Table 3. Results of flow in rate

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Tap angle Time Taken to fill 2 L (s)

Flow in rate (L/s)
(°) 1st 2nd Average
45 0 0 0 0
90 101.42 105.2 103.31 0.0194
135 26.13 26.22 26.18 0.0764
270 25.35 25.53 25.44 0.0786
360 25.12 24.37 24.75 0.0808
405 25.24 23.51 24.375 0.0821
450 23.16 24.25 23.71 0.0844
495 21.68 23.88 22.78 0.0878

Table 4. Results of flow out rate

Tap angle Time Taken to fill 2 L with Filter (s)

Flow out rate (L/s)
(°) 1st 2nd Average
45 0 0 0 0
90 107.37 105.92 106.645 0.019
135 29.18 28.87 29.03 0.0689
270 27.08 25.54 26.31 0.0760
360 27.68 23.33 25.51 0.0784
405 25.63 25.48 25.555 0.078
450 27.33 23.55 25.44 0.0786
495 24.7 23.16 23.93 0.0836

Graph in Figure 5 represents the relationship between the flow in rate and flow out rate.
The relationship equation is obtained to calculate the flow entering the slow sand filtration.
The flow out rate is represented as y and the flow in rate is represented as x. The flow out
rate represents the flow rate entering the slow sand filtration. Then, the surface area
required for the slow sand filtration is calculated using equation 1 and tabulated in Table 5.
Therefore, the slow sand filtration is designed based on the calculated surface area as
shown in Table 5. The sand filtration surface has 21 cm of radius. Therefore, the design can
be used up to maximum of 4-bedroom house. Based on Table 5, the maximum flow rate
entering the slow sand filtration is 54.76 L/h. Therefore, the maximum flow rate can be
handled by the slow sand filtration can be calculated using the Darcy’s equation as shown
below. The sand depth, d is recommended to be at least 50 cm by the environmental bodies
from United States. The hydraulic conductivity of the fine sand is given 2×10-4 m/s. The
depth of clearance above the sand layer is 10 cm.

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Graph of flow out rate against flow in rate

0.1
Flow Out Rate (L/s)

0.08
0.06
0.04
y = 0.9257x + 0.0004
0.02
0
0 0.02 0.04 0.06 0.08 0.1
Flow In Rate (L/s)

Fig. 5. Graph of flow out rate against flow in rate

Qmax = k.A.(h+d)/d
= (2×10-4) (π0.212) [(0.1+0.5)/0.5]
= 3.325×10-5 m3/s
= 119.70 L/h
Based on the calculated Qmax, the sand depth is designed to be 50 cm. This is because
the flow of water entering the sand filtration is lower than the maximum flow rate can be
handled by the slow sand filtration system with 50 cm sand depth. Based on the
experiments and calculation the final design of the system with collection tank is shown in
Figure 6 and Figure 7. The collection tank is design to collect 1000 L of capacity.

Table 5. Flow rate entering the slow sand filtration and surface area of sand

Flow rate Radius

Greywate
No of Daily water entering the Surface Area sand
r flow
bedrooms use (gal) sand filtration of Sand (m2) surface
rate (L/h)
(L/h) (cm)
1 or 2 225 35.49 32.85 0.08 16.17
3 300 47.32 43.80 0.11 18.67
4 375 59.15 54.76 0.14 20.87

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0.50

0.11

Fig. 6. 3D design of the system with the collection tank

2

C
1

B
NISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
BREAK SHARP
EDGES

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Fig. 7. Detailed design of the system with the collection tank

The design is evaluated by carrying out experiments to determine the COD, TSS and
turbidity value of the treated water using the small-scaled prototype. The data collected are
shown in Figure 8.

Graph of comparison between the standard water quality for

flushing and treated water
60

40

20

0
COD (mg/L) Turbidity (NTU) TSS (mg/L)
Standard water quality Treated water

Fig. 8. Bar chart comparison for standard flushing water quality and treated water

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The turbidity of the treated water in this experiments is less than 5 NTU. The total
suspended solid in the treated water is 3.33 mg/L. The TSS value required for the toilet
flushing water is less than 10 mg/L. Therefore, the design fulfils the requirement for the
TSS value. The COD of the treated water is 40 mg/L. The required COD for the toilet
flushing water is less than 30 mg/L. The COD requirement was not able to fulfilled because
of the small-scale prototype.
Based on the finalised design, the price to manufactured one complete filter system is
estimated. The complete system includes the plastic filter chassis for the pre-treatment filter
and slow sand filtration, filter sand, wire mesh, auto water pump and collection tank. The
price for each product is obtained and the total cost is calculated as shown in Table 6. The
experiments to evaluate the performance of system by measuring the TSS, COD, and
turbidity of the treated water are conducted using the prototype.
As can be seen in Table 6, the budget to manufacture one complete system using the
design in this project is lower than cost of the existing greywater recycling package. The
existing home scale greywater system in the market is a down-scaled of industry greywater
recycling design. Therefore, the cost of this existing home scale greywater recycling
package design is 8,100 USD. This design has high cost due to the technology that are used
in this system. This system consists physical treatment using different size of mesh and
membrane. Then, the biological treatment is carried out using the UV ray. The UV ray
neutralises the microorganism in the water. The parts that cause the system to be expensive
are the membrane, UV ray and pump. This design is relatively cheaper because this designs
does not uses any membrane as the physical filtration and high performance pump for the
water movement through the membrane. The membrane is replaced by the sand filtration
which able to meet the same turbidity and pump is replaced by the gravitational force in the
sand filtration. The UV ray is replaced by the sand filtration because the water and residue
accumulated at the top of the sand layer forms biological reaction bed layer. The
microorganisms are neutralised at top of the sand through biological treatment.

Table 6. List of price for the filtration system

Product Price Quantity Total (USD)

Filter chassis 25.80 USD/kg 10.073 259.8834
Auto water pump 133.43 USD 1 133.43
Filter fine sand 2.41 USD/kg 117 281.97
Gravel 2.31 USD/kg 80 184.8
1000 L water tank 425.55 USD 1 425.55
1 mm wire mesh 60 USD/sheet 1 60
0.5 mm wire mesh 80 USD/sheet 1 80
Total Cost (USD) 1425.63

Therefore, the optimisation of the design involves the cost of the system. The recycling
package is designed at relatively lower cost with same function and requirement. This low
cost provides more chances for the customer to buy this product. This can increase the
attention and business value of greywater recycling package.

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4. Conclusion
The greywater treatment package is successfully designed within proposed budget The
design of the system is within 6 m3 including the collection tank. The greywater treatment
package contains the pre-treatment filter, slow sand filtration and collection tank. The effect
of the pre-treatment stage on the flow entering the slow sand filtration is studied to design
the slow sand filtration. Based on the experiments, the slow sand filtration is designed
based on the volumetric flow rate and Darcy’s law. The material budget of a complete
system is lower than the existing home scale greywater recycling system. This design is
able to treat greywater to meet the standard water quality of toilet flushing.

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