ZERO LIQUID DISCHARGE THROUGH PULP & PAPER INDUSTRY

SUBMITTED BY: SOORAJ GARG

P14EN009

UNDER THE GUIDANCE OFDr. Namrita D JariwalaAssistant Professor Department of Civil EngineeringSV National Institute of Technology

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CONTENT

• Introduction• Pulp and Paper industry• Zero Liquid Discharge• Case Study• Discussion • Looking Forward• References

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INTRODUCTION

• Nowadays, the scarcity of water is a concerning reality and the environmental aspects has become a major priority, that leads the industries towards the method that can reduce the generation of wastewater or can reuse this.

• Zero Liquid Discharge (ZLD) – Help to achieve environmental compliance, – Reduce carbon footprint, – Create positive public perception, – Recover high purity water for reuse

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5Staudust 2010

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WASTE WATER TREATMENT PROCESS IN THE PAPER AND PULP INDUSTRY

Office of Air Quality Planning and Standards EPA, October 2010

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ENVIRONMENT IMPACT / CONCERNS OF PULP AND PAPERMANUFACTURING PROCESS

The major environmental issues faced by the pulp & paper industry are: Control of color and AOX discharge Control of release of Non Condensable Gases (NCG’s). Disposal of Solid waste viz. Lime Sludge/Fly ash.

Recycling of process water (instead of freshwater use) is limited by the accumulation of dissolved matter from wood and other raw materials entering the process.

Some of the problems associated with contaminant accumulation are deposition and scaling, foaming, corrosion, stream dead load, and degradation of the end product quality parameters

The Ministry of Environment & Forest (MoEF) has launched the Charter on "Corporate Responsibility for Environmental Protection (CREP)" in March 2003 with the purpose to go beyond the compliance of regulatory norms for prevention & control of pollution through various measures including waste minimization, in-plant process control & adoption of clean technologies.

Zero Liquid Discharge, Cleaner production are the most focus approaches in this CREP.

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ZERO LIQUID DISCHARGE• Zero Liquid Discharge (ZLD) is a series of processes (like

membrane filtration, reverse osmosis, evaporation and crystallization) that extract pure water from industrial effluents, leaving behind sludge, dissolved solids, suspended particles and salt crystals

• Pre-requisite for ZLD needs physical and chemical treatment and followed by biological system to remove organic load.

• The treated effluents can be subjected for concentration and evaporation.

• The concentration method quite often involves the adoption of Reverse Osmosis (RO) and Nano Filtration (NF) methods.

• The evaporation methods involve incineration/drying/ evaporation of effluent in multi effect evaporators (MEE).

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NEED OF ZLD • Most polluting industries such as Pharma, Pulp & Paper, Tanneries, Textile,

Dyeing, Chemicals, Power Plants etc. generate wastewater with high salinity/TDS.

• Conventional ‘Physico - chemical biological’ treatment does not remove salinity from the treated effluent. The TDS content is well above the statutory limit of 2100 mg/L.

• Discharge of saline but treated wastewater pollutes ground and surface waters.• Several states in India including Tamil-Nadu are water stressed. Competing

demands for water from agriculture and domestic use has limited industrial growth.

• TN has taken a lead on ZLD due to absence of fully flowing perennial rivers Other states such as Gujarat and Karnataka also considering ZLD.

• MAIN MOTIVATORS – Water Scarcity, water economics, regulatory pressure.

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LEGISLATION RELATED TO ZLD IN INDIA• Supreme Court directed Polluting pharmaceutical industries near Hyderabad to pay

farmers Rs 4000/ acre annually (between 1992-2002) due to loss of soil fertility • Tamil Nadu High Court Order mandated ZLD for dyeing, bleaching units, tanneries

and distilleries. (2006) • Andhra Pradesh High Court order mandated ZLD for 12 large Pharmaceutical units

around Hyderabad discharging 25,000 kld (2008) • Tamil Nadu Government and Central Government Scheme for a subsidy of Rs. 320

crore (interest free loan) to set up ZLDs in the state following the court order of 2006.(2010)

• Punjab Pollution Control Board mandated ZLD in 8 large electroplating industries in Ludhiana (2010)

• Punjab Pollution Control Board assisted 500+ small electroplating units in Ludhiana to set up a CETP with ZLD (2010)

• Rajasthan Government declared a Capital Subsidy on zero liquid discharge based effluent treatment plant equivalent to 20% of amount paid to the suppliers for the plant excluding civil work, subject to a maximum of Rs. 1 crore (2014)

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APPROACHES TO ZLD

CPCB

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BENEFITS OF ZLD• To save costs and reduce the capacity needed.• High operating costs can be justified by high

recovery of water (>90-95%) and recovering of several by products from the salt.

• A more sustainable growth of the industry while meeting most stringent regulatory norms

• Reduction in water demand from the Industry & frees up water for Agriculture and Domestic demands.

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CHALLENGE IN ZLD• While the benefits of ZLD are significant, adoption of the technology

has two key ‘environmental’ considerations: Energy consumption for the evaporation process Disposal of the solid waste. • The energy cost for evaporation accounts for over 90% of the

operational expenses of ZLD• There is also the issue of dealing with the highly toxic rejects of a

ZLD plant. Presently in Tamil Nadu, there are designated landfill zones (away from the industrial centers) for disposal of the sludge.

• This increase the cost for the manufacturers because they have to store the sludge (often for up to a year) before transporting it to far off locations, but this also does not resolve the issue of waste disposal

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PROFILE• Project Assessor/Company – Tamil-Nadu Water Investment Company

Limited (TWIC)• Client – Tamil-Nadu Newsprint and Papers Limited, Karur• TWIC Role - Implementation and operation of the pilot plant and preparation

of technical and commercial feasibility report as a precursor to development, financing, implementation and operation of Zero Liquid Discharge facility.

• Benefits of this Project - The project would enable the Pulp & Paper Mill reducing its water consumption and further improve on the quality of treated wastewater used for irrigation.

• Current Status - 120 m3/day pilot plant has been successfully demonstrated. A full scale plant is now proposed.

• Operation - The pilot plant was erected & commissioned in October 2011. Pilot plant performance were evaluated for 6 months with hard wood bleach effluent, further evaluations were carried out for another 2 months. Data generated based on the piloting provided inputs for designing of full scale plant

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TECHNICAL SPECIFICATIONS.

NoParameters Range*

1 pH 5.0 - 6.0

2 BOD 900 – 1100

3 COD 2000 – 3400

4 TSS 450 – 1000

5 TDS 4500 – 5800

6 Cl- 1500 – 2000

7 SO42- 500 – 600

8 Total Hardness 900 – 1200

* All Ranges are in mg/L except pH

Source : Husain S. I. 26 April 2013

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RESULTS• Approx. 93.70% of waste was recovered and

only 6.30% of effluent was remain to dispose.

• TDS level of wastewater was removed up to 96% in this pilot study

• A High amount of RO water produced (Approx. 81% of Effluent)that is reused in agriculture.

• By-products generated, such as, Sulfate and Lime sludge can be used within the premises.(A cement Industry is their)

• The high quality brine generated can be sold off to other industries, such as, dyeing industries or industrial salt manufacturers.

• For a 10 MLD plant 21.8 tons/day of Na2SO4 and 36.3 tons/day of lime sludge is expected.

• water consumption of the pulp mill will come down from 50 m3/ MT to 43 m3/ MT. Source : Husain S. I. 26 April 2013

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QUALITY OF VARIOUS RECOVERED BY-PRODUCT

Source : Husain S. I. 26 April 2013

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DISCUSSION• A first step towards the Zero Liquid Discharge, for recycling of effluent is

Reverse osmosis followed by Nano filtration and Ultra filtration.• Zero Liquid discharge, for industries like integrated Paper mills, Power

Plants etc. is feasible for environmental concern as well as economic point of view.

• During this pilot plant study, some hurdles like variation of parameters such as pH, sulfates, chlorides were observed but however they are partially stable and provides flexibility and robustness to the study

• ZLD approach is feasible for large industries but achieving partial ZLD for Small-medium scale industries also possible with reuse of wastewater with the help of Reverse osmosis and some other membrane technology.

• Recovery of chemicals in their pure forms from the effluent stream which can then be re-used in the manufacturing process or sold in the market. Thus, “it is possible to make ZLD profitable. Even though the capital expenditure may be high, the breakeven period is within two years”

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LOOKING FORWARD• Addressing cost Challenges with Existing ZLD – Choosing of cheaper alternate that adversely affect– Maintenance - If the ZLD system is Under performing or shut,

factories have to operate at lower capacity or stop operations• Fiscal incentives to promote ZLD – Government can subsidize the initial capital expenditure of

ZLDs– use of Green Stamps in products to encourage consumers to

move towards sustainable consumption• To view the effluent not as a waste stream, but as a

resource stream. The cost of treatment then actually becomes a manufacturing cost

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INDUSTRIES AND REGIONS MOST LIKELY TO REQUIRE MANDATORY ZLD IN THE NEAR FUTURE

• The Central Pollution Control Board (CPCB) surveyed 88 industrial clusters in the country and determined the level of air, surface water and land (ground water) pollution of those clusters in 2009.

• As per the CPCB Report (2013), 15 of these clusters have critical levels of surface water pollution, 5 have critical levels of ground water pollution and 3 have critical levels of both surface and ground water pollution

• Out of these 23 clusters, 15 lie in regions where there is scarcity of ground water which indicates a greater need for water conservation and treatment in these 15 regions.

22CPCB 2013 Interim Report, Central Water Board Ground Water Assessment, 2013

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REFERENCES

1. Bhaskaran S., Palanisamy C., Chinnaraj S., “Two Stage Causticizing at TNPL for Effective Limekiln operation and to reduce silica build up in recovery cycle”

2. Business Standards, IPPTA J, Vol. 22, No.3 July –Sep, 2010, p.3. Carmen M, Teresa C, and Francisco A. C, ”Recovering wastes from the paper industry: Development of

ceramic materials”, J. of Fuel Processing Technology, No. 103, 2012, pp. 117-1244. Chakrabarty K, Vamsee K. K., Saha P, Ghoshal A K, “Extraction and recovery of lignosulfonate from its

aqueous solution using bulk liquid membrane”, Journal of Membrane Science 330 (2009) 135–1445. Dixon G.N., “Achieve Zero liquid Discharge of Industrial Waste”, Samsco water Evaporators.6. Eloranta, J. ‘Indian pulp & paper industry- challenges and opportunities” In paper International, January-

March 2010, p.12 7. Hussain S.I., “Industrial water recycling in the Textile Dyeing CETP in Tirupur”, IFAT India, Oct. 9-11

2014.8. Hussain S.I. , “Zero Liquid Discharge Facility for Pulp and Paper Effluents – a case study”, State level

workshop report: Environment friendly Techniques in Pulp & Paper, Vapi Gujarat, 26th April 20139. Johnson T, Johnson B, Mukherjee K, Hall A, ”India- An emerging giant in the pulp and paper Industry”,

65th Appita Annual Conference Rotoura.10. Kumar, A. “The challenge of finding raw material supplies”. (RISI Indian Seminar, New Delhi, December

2009).

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THANK YOU