Membranes for Industrial Membranes for Industrial Wastewater Recovery and Re-use To Claire, Oliver and Samuel Membranes for Industrial Wastewater Recovery and Re-use Edited by: Simon Judd and Bruce Jefferson E L S E 1- 1 i5 R UK USA JAPAN Elsevier Science Ltd, The Boulevard, Langford Lane, Kidlington, Oxford OX5 lGB, UK Elsevier Science Inc, 360 Park Avenue South, New York, NY Elsevier Japan, Tsunashima Building Annex, 3-20-12 Yushima, Bunkyo-ku, Tokyo 113, Japan 10010-1710, USA Copyright 0 2003 Elsevier Ltd. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means: electronic, electrostatic, magnetic tape, mechanical, photocopying, recording or otherwise, without prior permission in writing from the publishers. British Library Cataloguing in Publication Data Membranes for industrial wastewater recovery and re-use 1 .Water reuse 2.Membranes (Technology) 3.Water - Purification - Reverse osmosis process I. Judd, Simon 628.1'674 ISBN 1856173895 Library of Congress Cataloging-in-Publication Data Judd, Simon 11. Jefferson, Bruce Membranes for industrial wastewater recovery and re-use / Simon Judd and Bruce Jefferson. Includes bibliographical references and index. 1. Sewage-Purification. 2. Factory and trade waste-Purification. 3. Membranes (Technology) 4. Water reuse. I. Jefferson, Bruce. 11. Title. p. cm. ISBN 1-8561 7-389-5 TD754.J83 2003 62 8.3'5241~2 1 2003040757 No responsibility is assumed by the Publisher for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions or ideas contained in the material herein. Published by Elsevier Advanced Technology, The Boulevard, Langford Lane, Kidlington Oxford OX5 lGB, UK Tel.: +44(0) 1865 843000 Fax: +44(0) 1865 843971 Typeset by Variorum Publishing Ltd, Lancaster and Rugby Printed and bound in Great Britain by Biddles Ltd, Guildford and King's Lynn Contents Preface Contributors Chapter 1 Introduction 1.1 1.2 Industrial water 1.3 Membrane technology 1. I Water reuse motivations and barriers Chapter 2 Membrane technology 2.1 2.2 2.3 2.4 The membrane 2. I. 1 2. I .2 Membrane structure 2. I. 3 2.1.4 Membrane configurations The process fundamentals 2.2.1 Process performance definitions 2.2.2 The driving force 2.2.3 2.2.4 Critical flux The theory 2.3.1 Membrane mass transfer control 2.3.2 Process design and operation 2.4.1 Staging 2.4.2 Specific energy demand 2.4.3 Fouling and pretreatment 2.4.4 Backwashing and cleaning References Membrane and membrane process definition Membrane materials and their manufacture Factors opposing the driving force Fouling/cake layer mass transfer control ix xiii 2 4 7 14 14 14 17 23 32 32 34 34 39 40 41 43 52 52 55 59 66 70 vi Membranes for Industrial Wastewutrr Recovery and Re-use Chapter 3 Industrial waters 3.1 3.2 3.3 3.4 3.5 The power industry: water requirements for power generation and cooling water 3.1.1 Water demand by the power industry 3.1.2 Overview ofcooling water systems 3.1.3 Overview of boiler feedwater systems 3.1.4 Sources of water used for 3.1.5 Water quality comparisons 3.1.6 Optimisation of water use in recirculating cooling systems 3.1.7 Cooling tower water quality issues 3.1.8 Governing legislation and guidelines 3.1.9 Volumes and quality of aqueous process waste streams 3.1.10 Current reuse practices and opportunities References The pulp and paper industry 3.2.1 Introduction 3.2.2 3.2.3 Effluent volumes and quality 3.2.4 3.2.5 3.2.6 Conclusions Acknowledgements References The textile industry 3.3.1 Categories of textile processing operations 3.3.2 Effluents from textile processing unit operations 3.3.3 Process water quality requirements 3.3.4 Legislation 3.3.5 Conventional treatment 3.3.6 Demand management 3.3.7 Reuse practice and opportunities References The beverage industry 3.4.1 Point of use recycling opportunities 3.4.2 End of pipe recovery opportunities References Pure waters in the pharmaceutical industry 3.5.1 Background 3.5.2 Water quality standards 3.5.3 3.5.4 Reuse opportunities Pulping and paper manufacturing processes Current water and effluent purification systems and governing legislation Membranes in the pulp and paper industry Volumes and quality of aqueous process and waste streams 76 76 77 80 80 81 85 88 93 94 95 100 102 102 104 106 113 115 125 125 125 132 132 133 143 144 146 148 149 154 159 159 160 163 163 163 164 167 169 Contents vii Chapter 4 System design aids 4.1 Computer-aided design for reverse osmosis plant 4.1.1 Introduction 4.1.2 4.1.3 RO design software 4.1.4 Cost calculation 4.1.5 Overview References 4.2.1 Introduction 4.2.2 Water pinch: the history 4.2.3 Methodology 4.2.4 Computed solutions 4.2.5 Software tools currently available 4.2.6 4.2.7 Conclusion References 4.3 Design examples 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 Key elements of the reverse osmosis process 4.2 Water pinch analysis Case study: water pinch and implementation of regeneration techniques Problem in reverse osmosis: film theory and energy demand Problem in reverse osmosis: array design Problem in reverse osmosis: CAD array design Problem in electrodialysis: energy demand Problem in submerged membrane filtration design Chapter 5 Case studies 5.1 5.2 5.3 5.4 Flag Fen high-purity water production plant (UK) 5.1.1 Background 5.1.2 Description ofplant 5.1.3 Performance Eraring Power Station: purification of secondary sewage for boiler feedwater (Australia) 5.2.1 Background 5.2.2 Description ofplant 5.2.3 Performance Doswell combined cycle power plant: zero liquid discharge (USA) 5.3.1 Background 5.3.2 Description of system 5.3.3 Performance VHP Ugchelen: paper mill water recycling (Netherlands) 5.4.1 Background 172 172 172 176 182 183 186 186 186 187 187 191 197 201 209 209 213 213 216 217 220 223 228 228 228 2 30 232 232 233 235 237 237 238 2 40 241 241 5.4.2 Description of system 242 [...]... 0.2 Cl 6.0-8.5 . 15 7 19 5 15 4 - 16 0 11 8 13 6 15 5 15 1 13 0 10 4 228 17 2 16 6 14 5 18 8 10 0 59 96 58 52 10 7 69 76 37 58 12 0 10 0 77 42 70 97 54 54 49 58 81 43 95 69 255 237 16 3 16 0. 5.3.3 Performance VHP Ugchelen: paper mill water recycling (Netherlands) 5.4 .1 Background 17 2 17 2 17 2 17 6 18 2 18 3 18 6 18 6 18 6 18 7 18 7 19 1 19 7 2 01 209 209 213 213 216 217 220. 12 5 12 5 12 5 13 2 13 2 13 3 14 3 14 4 14 6 14 8 14 9 15 4 15 9 15 9 16 0 16 3 16 3 16 3 16 4 16 7 16 9 Contents vii Chapter 4 System design aids 4 .1 Computer-aided design for reverse osmosis