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Wastewater treatment
for Dyestuff Industry
Introduction
Types of Dyes
Direct dyes:
In most of the small dyeing houses, direct dyes are used as they are easy to apply
and no auxillary chemicals such as mordants are needed.
Basic dyes:
Sulfur dyes:
Vat Dyes:
These are water insoluble and fast dyes applied along with strong reducing agents (sodium hydro
sulfite) and alkali to make the dye soluble. The cloth is then exposed to air for
oxidation. The excess alkali remaining on the cloth is neutralized by scouring i.e
treatment with dilute solution of acid. This types of dyeing generates more volume of
effluents, as at the end of each step, the clothes are warmed
Naphthol dyes :
Beta-naphthol is first applied to the fabric, dried and treated with a developer for
coupling and diazotization after which the colour is formed. This is followed be soaping and
alkali treatment.
Developing dyes :
In this dyeing, the dyes are applied, dried and treated with sodium nitrite and acid
and finally with
.
Dyes pH BOD Gallon
wastes per
1000 lb
goods
1. Temperature 50º C
2. pH value 10.5
Gaseous emissions such as SO2, Properly designed scrubber with recovery reuse
NO2, HCl, and NH3 are generally of scrubbed liquid is required.
scrubbed.
Gypsum, iron sludge and sludge Cleaner process technologies e.g. catalytic
from ETP are generated as solid hydrogenation, use of spent acid after nitration
waste. The gypsum and iron for acidification of fusion mass, which can
sludge can be used in the cement eliminate generation of iron and gypsum sludge.
and pigment industries, The sludge
is either disposed off on
land/secured landfill or sent to
other user industries.
PRIMARY TREATMENT
Screening
Equalization
Neutralization
Chemical coagulation
Screening
Screening is the first treatment station, both for surface and wastewater. It's
purpose to:
• Protect the structure downstream against large objects which could create obstructions
in some of the facility's units,
• Easily separate and remove large matter carried along by the raw water, which might
negatively affect the efficiency of later treatment procedures or make their
implementation more difficult.
The efficiency of the screening operation depends of the spacing between screen bars:
Usually the fine screening is preceded by a preliminary screening operation for purposes
of protection.
Screening is carried to out by a manually cleaned bar screen (large in size, in order to
reduce the frequency of screenings collection operations) or, preferably, by an automatically
cleaned bar screen (essential in cases of high flow rates of for water with a high solids
content). The automatic bar screen is usually protected by a sturdy preliminary bar screen,
which should also be provided with an automatic cleaning systems in large facilities and in
case of raw water containing a high volume of coarse matter.
The collected refuse is stored in a container of given capacity, calculated according the
acceptable frequency of refuse disposal operations.
HYDRAULIC SIZING-CLOGGING :
Under normal circumstances, the crossing velocity through the bar screen should be
sufficient for matter to attach itself to the screen without producing an excessive loss of head
or a complete clogging of the bars, or allowing matter to be carried by the flow; normally
acceptable crossing velocities between bars average between 0.6 and 1.0 m.s-1 and 1.2 to 1.4
m.s-1 at the maximum water flow.
These velocities apply to the area of the clogged bar screen that is still clear. The
degree screen that is still clear. The degree of clogging depends on the water quality and on
the system used to recover waste from the bar screen. For automatic bar screens it can be
anywhere between 10% (surface water) and 30% wastewater with a high solids content). For
manually cleaned bar screens, the area of immersed bar screen must be larger, so as to avoid
frequent cleanings.
In general, the bar screens cleaning systems works on an intermittent basis. It can be
controlled in three ways:
c) by a combination of both systems. When the bar screen is located downstream from a
pumping station, the control mechanism can be linked to start-up of the pumps, with a built-
in timer to keep the screen in operation for 1 to 30 minutes.
Automatic bar screen must be equipped with torque limiter to prevent equipment damage in
case of overloading or blocking.
Normally, reciprocating cleaning bar screens, both curved and straight, include a device to
ensure that the rake automatically stops moving at a point outside of the screen area, so as to
avoid jamming upon restarting.
DIFFERENT TYPES OF SCREENS :
PARABOLIC SCREEN
CURVED SCREEN
In operation, sewage flows though the inclined screen, approaching from the upstream side
and after passing through the screen, departing on the downstream side. The screen is
periodically raked by a mechanized comb system which is actuated either by level switches
mounted in the channel upstream of the screen or by time clock. A doctor blade at the top of
the comb travel removes the screenings collected by the moving combs.
The moving combs are suspended between two endless side chains, which are driven through
a head shaft, and sprockets. The gear motor and moving comb system is protected from
damage caused by jamming by a torque overload coupling with a micro switch.
The screenings removed from the doctor blade drop onto a skid plate, which transports the
screening down to a container, belt conveyor or sluice pipe.
CURVED BAR SCREEN
This type 2 bar screens uses hydraulics to ensure a simple kinematical operation, you can see
it in the following picture
2. Moving frame
4. Rake carriage
5. Lifting jack
6. Ejector
7. Electrical cabinet
8. Latticed covers
9. Hydraulic unit
In operation, sewage flows though the curved screen, approaching from the upstream side
and after passing through the screen, departing on the downstream side. The screen is
periodically raked by a mechanized comb which is actuated either by level switches mounted
in the channel upstream of the screen or by time clock. The screenings collected by the
moving comb are cleaned from the comb by a doctor blade at the top of the comb travel.
The screenings removed from the doctor blade drop onto a skid plate, which transports the
screening down to a container, belt conveyor or sluice pipe.
Features and operation are similar to the curved bar screen. The drive mechanism is simpler
for small installations and will remove a larger quantity of screenings due to two cleanings
per revolution.
STEP SCREEN
Step screens have become popular with some clients due to their ability to remove smaller
sized solids than the bar type screens. We have access to several makes of this type of
machine.
BRUSH TYPE INCLINED SCREEN
These units are inclined screens with a rotary brush type belt cleansing system. This device is
strongly favored by some clients instead of the step screen.
STATIC SCREEN
These devices are for smaller flows and require manual cleansing. They may be of the
inclined bar type or the parabolic static sieve bend. This latter type can remove solids down
to 0.5mm size.
SCREENINGS HANDLING
As a result of the increased volume of entrained sharp objects such as hypodermic syringes
and the like, mechanical screenings handling equipment now has a higher profile in the
process designers strategy.
Equipment such as dewatering processes, shaftless screen conveyors and bagging units are
available through our company
The following chart shows the Upstream cleaning mechanical bar screens
Type of the bar Cleaning Depht of Widht of Bar spacing Bar Thickness Height of Water
screen operation channel (m) channel (m) (mm) (mm) disposal (m) depht (m)
Medium Curved bar Contin. 0.75 to 1.75 0.5 to 1.6 10 to 40 10 0 0.50 to 1.5
screening screen GDH
type
Hydraulic Recipr. 0.75 to 2.80 0.6 to 1.2 10 to 40 10 0 to 1.2 0.50 to 1.5
staight bar
screen GDH
type
Cable straight Recipr. 2.00 to 10.0 0.1 to 2.6 10 to 40 10 0.65 and 1.2 1.5 to 9.5
bar screen
GDC type
Rack and Recipr. 1.50 to 5.00 0.6 to 2.0 12 to 80 0.65 and 1.3
pinion bar
screen
Grab bar Recipr. 2.50 to 10.0 1.5 to 10 12 to 100
screen
Fine Fine curved Contin. 0.75 to 1.75 0.5 to 1.6 1 to 10 0 0.50 to 1.5
screening bar screen
GFC Type
Fine straight Contin. 2.0 to 10.0 1.0 to 2.6 1 to 10 0.85 and 1.2 1.5 to 9.5
bar screen
GFD type
Endless moving Contin. 0.6 to 15.0 0.3 to 4.0 1 to 15 0 to 1.2 0.4 to 14.5
bar screen
Flow Equalization
Flow equalization is the process of controlling hydraulic velocity, or flow rate, through a
wastewater treatment system. The equalization of flow prevents short term, high volumes of
incoming flow, called surges, from forcing solids and organic material out of the treatment
process. Flow equalization also controls the flow through each stage of the treatment system,
allowing adequate time for the physical, biological and chemical processes to take place.
1. In the case of a septic tank or pretreatment tank, gravity separation of solids is greatly
enhanced. This prevents short-circuiting and eliminates excess solids from being carried
downstream into the secondary treatment facility or disposal system.
3. Clarifiers following secondary treatment will have greater solids separation and improved
effluent quality. If a filtration device is used, solids loading to the filtration device will be
reduced, resulting in longer filter life and higher effluent quality.
4. The operation of a downstream sand filter, media filter or constructed wetland is enhanced
by more consistent loading, the equalization of surge flows and the removal of excess solids.
5. All types of effluent disposal systems, including tile fields, mounds, irrigation systems,
etc., will operate longer and more efficiently because organic and hydraulic surges are
eliminated and system overloading is prevented.
These benefits clearly demonstrate the important role flow equalization can play in
wastewater treatment. Incorporating flow equalization into residential onsite treatment
systems makes any system perform better and prevents premature failure
Neutralization
Dyes increase alkalinity of water which makes it unfit for aquatic life.
Trickling filter
Activated sludge process
Aerated lagoon
Oxidation pond
Oxidation ditch
Aerobic Degradation of Dyes
Anaerobic digestion
Biosorption
Trickling filter
Oxidation pond
Inefficient treatment
Resistance to biological oxidation
Poor adsorption of dyes
Example : Three anionic dyes i.e CL reactive violet 15, reactive blue
19 and reactive red 5 were neither removed nor biodegraded by
activated sewage sludge even after 20 days of incubation.
Similar findings for sulphonated water soluble dyes.
Examples of fungus
Examples of Bacteria
Tertiary treatment
Reverse osmosis
Electrodialysis
Ultrafiltration
Adsorption on powered activated carbon
Membrane filtration
Nanofiltration
Reverse Osmosis
The ionic components (heavy metals) are separated through the use of semi-
permeable ionselective membranes.
Application of an electrical potential between the two electrodes causes a
migration of cations and anions towards respective electrodes.
Because of the alternate spacing of cation and anion permeable membranes,
cells of concentrated and dilute salts are formed.
The disadvantage is the formation of metal hydroxides, which clog the
membrane.
Ultrafiltration
.
They are pressure driven membrane operations that use porous
membranes for the removal of heavy metals. The main disadvantage of this
process is the generation of sludge
It is very effective for adsorbing cationic, mordant and acid dyes, and to a
slightly lesser extent, dispersed, direct, vat, pigment and reactive dyes.
Membrane filtration
Membrane filtration can clarify, concentrate and separate dye continuously from
effluent.
Disadvantages – disposal of the residue, high capital cost and the need for
membrane replacement.
Nanofiltration
Sr.No. Characteristics
Toleranc
e limits
1. pH value 5.5 to 9.0
5. Colour
Absent