Waste minimization study in a solvent-based paint manufacturing plant

Solvent-based paint manufacturing plants produce significant quantities of hazardous waste, which must be properly treated before it can be disposed. Since the cost for treating this waste is high, reducing the quantity of waste has become a crucial issue in this industry.Waste minimization options are beneficial for the owner of the plant as well as for the environment. The quantity of hazardous waste can be minimized by changing the plant's technology or by substituting hazardous substances, which are used in the paint manufacturing process, with environmentally friendly ones. Furthermore, separating the various waste streams makes it easier to recover raw materials and enhances the possibility of their reuse within the production process. This will decrease operational costs for the plant.This paper presents a case study of waste minimization in a solvent-based paint manufacturing plant. Source reduction, recovery, and recycling methods are taken into consideration. Its aim is to develop an understanding of the facility's waste generating processes, to suggest ways to reduce the waste production, and finally to select an appropriate waste minimization option to suggest to the plant. Some of the suggested methods are currently being practiced while others are at initial stage of development.     

Optimization of "Serpa" cheese whey nanofiltration for effluent minimization and by-products recovery

Second cheese whey (SCW) is a by-product of cheese and curd cheese production that is usually not recovered and therefore substantially contributes to the negative environmental impact of the cheese manufacture plants. Membrane technology, namely nanofiltration (NF), is used in this work for the recovery of SCW organic nutrients, resulting from "Serpa" cheese and curd production. The SCW is processed by NF to recover a rich lactose fraction in the concentrate and a process water with a high salt content in the permeate. The permeation experiments were carried out in a plate & frame NF unit, where two NF membranes (NFT50 and HR-95-PP) were characterized and tested. The NF permeation experiments were performed accordingly with two different operation modes: total recirculation and concentration. In order to select the best membrane and operating pressure for the SCW fractionation, total recirculation experiments were carried out. The NF modeling was also performed, in terms of permeate fluxes and rejection coefficients using the resistances-in-series model and the solution-diffusion model, respectively. After the membrane selection, the concentration experiments showed that the selected membrane (NFT50) at 3.0MPa allows a water recovery of approximately 80%, concentrating the SCW nutrients approximately 5 times. Therefore, the NF operation can successfully reduce the wastewater organic load and simultaneously contributes to the valorization of the cheese and curd cheese manufacture by-products.     

Making or breaking waste facility siting successes with a siting framework

Waste facility siting successes depend on many linked factors of facility design and impacts, site characteristics, and community beliefs and values. A facility siting framework is constructed to combine important elements and cause–effect linkages that affect the siting outcome. The framework consists of three main components: (1) core elements of facility design, effects, and community beliefs, attitude and response; (2) contributing factors of site and community characteristics, community beliefs and values that affect the interpretation of the facility and its effects; and (3) siting management interventions to manage the process and facility impacts. The framework is applied in an unsuccessful and a successful siting case to determine the key elements that contribute to siting outcome: (1) thorough need justification for the facility from the proponent's and the community's perspective; (2) careful facility design and prediction of the impacts and to select impact management compensation measures; (3) screening and selection of communities where the beliefs and values are compatible with the type of facility and its effects, (4) cooperatively selected impact reduction (i.e., prevention, control, and mitigation) measures followed by compensation and incentives; and (5) intensive process management to balance the community characteristics and values with the proponent's efforts to plan, design, assess and manage impacts, and ultimately, gain approval of the facility. The siting framework provides a comprehensive and robust structure of key factors that contribute to siting outcome and, therefore, provides the tool to identify, evaluate, and design siting interventions to enhance the chances of successful siting outcome.     

Anaerobic-aerobic treatment of purified terephthalic acid (PTA) effluent; a techno-economic alternative to two-stage aerobic process

This paper addresses the treatment of purified terephthalic acid (PTA) effluent using anaerobic and aerobic processes. Laboratory studies were carried out on flow proportionate composite wastewater generated from the manufacturing of PTA. An activated sludge process (ASP-two stage and single stage) and an upflow anaerobic fixed film fixed bed reactor (AFFFBR) were used, individually and in combination. The performance of a full-scale ETP under existing operating conditions was also studied. Full scale ETP studies revealed that the treatment of PTA effluent using a two-stage ASP alone does not meet treated effluent quality within the prescribed Indian Standards. The biomass produced in the two stage ASP was very viscous and fluffy and the sludge volume index (SVI) was very high (200-450 ml/g). However, pretreatment of PTA effluent using an upflow AFFFBR ensured substantial reduction in BOD (63%) and COD (62%) with recovery of biogas at 1.8-1.96 l/l effluent treated at a volumetric loading rate (VLR) 4-5 kg COD/m(3) d. The methane content in the biogas varied between 55% and 60%. The pretreated effluent from the upflow AFFFBR was then treated through a single stage ASP. The biomass produced in the ASP after anaerobic treatment had very good settlability (SVI: 75-90 ml/g) as compared to the two stage ASP and the treated effluent quality with respect to BOD, COD and SS was within the prescribed Indian Standards. The alternative treatment process comprising an upflow AFFFBR and a single stage ASP ensured net power saving of 257 kW and in addition generated 442 kW of power through the AFFFBR.     

Environmental impact minimization of a total wastewater treatment network system from a life cycle perspective

Synthesis of distributed wastewater treatment plants (WTPs) has focused on cost reduction, but never on the reduction of environmental impacts. A mathematical optimization model was developed in this study to synthesize existing distributed and terminal WTPs into an environmentally friendly total wastewater treatment network system (TWTNS) from a life cycle perspective. Life cycle assessment (LCA) was performed to evaluate the environmental impacts of principal contributors in a TWTNS. The LCA results were integrated into the objective function of the model. The mass balances were formulated from the superstructure model, and the constraints were formulated to reflect real wastewater treatment situations in industrial plants. A case study validated the model and demonstrated the effect of the objective function on the configuration and environmental performance of a TWTNS. This model can be used to minimize environmental impacts of a TWTNS in retrofitting existing WTPs in line with cleaner production and sustainable development.     

Industrial experience of process identification and set-point decision algorithm in a full-scale treatment plant

This paper presents industrial experience of process identification, monitoring, and control in a full-scale wastewater treatment plant. The objectives of this study were (1) to apply and compare different process-identification methods of proportional-integral-derivative (PID) autotuning for stable dissolved oxygen (DO) control, (2) to implement a process monitoring method that estimates the respiration rate simultaneously during the process-identification step, and (3) to propose a simple set-point decision algorithm for determining the appropriate set point of the DO controller for optimal operation of the aeration basin. The proposed method was evaluated in the industrial wastewater treatment facility of an iron- and steel-making plant. Among the process-identification methods, the control signal of the controller's set-point change was best for identifying low-frequency information and enhancing the robustness to low-frequency disturbances. Combined automatic control and set-point decision method reduced the total electricity consumption by 5% and the electricity cost by 15% compared to the fixed gain PID controller, when considering only the surface aerators. Moreover, as a result of improved control performance, the fluctuation of effluent quality decreased and overall effluent water quality was better.     

The reuse of municipal solid waste incinerator fly ash slag as a cement substitute

The results of the treatment of fly ash from a municipal solid waste incinerator (MSWI) by melting are described, and the safety and the effectiveness of using the slag produced by this melting treatment are studied. The properties of the MSWI fly ash slag were analyzed, to evaluate the feasibility of its reuse as a substitute for part of the cement required in mortar preparation. This MSWI fly ash slag was found to be comprised mainly of SiO₂ and CaO, which can be substituted for up to 20% of the cement content in mortar, without sacrificing the quality of the resultant concrete. In fact, the concrete thus produced has greater compressive strength, 10% higher than that without the substitution. The setting time of the fresh mortar becomes lengthens as increasing amounts of cement are replaced; while the spread flow value increases with the increasing percentage of cement substitution. X-ray diffraction analysis reveals that when the W/C=0.38 and the curing AGE=28 days, the crystal patterns in the mortar samples, prepared with different amounts of cement having been replaced by MSWI fly ash slag are similar. According to the results of the toxic characteristic leaching procedure analysis, MSWI fly ash slag should be classified as general non-hazardous industrial waste, that meets the effluent standard. Therefore, the reuse of MSWI fly ash slag is feasible, and will not result in pollution due to the leaching of heavy metals.