TECHNO-ECONOMIC FEASIBILITY
STUDY OF ZERO LIQUID DISCHARGE
DR. MRITUNJAY CHAUBEY
ABSTRACT
Zero liquid discharge (ZLD) is a wastewater
management technique that eliminates liquid waste
discharge going outside of operating plants. This has
attracted renewed interest worldwide in recent years.
The concept of establishment of ZLD may be good
but it cannot be generalized and implemented hastily
and uniformly over the entire country as it emits more
carbon leading to global warming and generate huge
amount of hazardous solid waste occupying more
landfill land. Further ZLD also requires high operation
and maintenance cost for its execution and running.
In this paper, we have done comparative techno-
economic feasibility study for 2.5 MLD capacity effluent
treatment plant (ETP) to meet the standard discharge
norms and to meet ZLD norms based on environmental
parameters considering power consumption,
CO2 emission, solid waste generation & chemical
consumption and economic parameters considering
capital expenditure & operational expenditure.
Implementation of ETP to meet ZLD norms will require
more land which may not be available with the industry
within premises or in the adjoining area. Each state
has its own uniqueness about its eco system and the
environment. The disposal of treated effluent inside
the Sea/Estuary is a better choice as huge dilution is
available and the impact on the marine eco system will
be minimum.
1
INTRODUCTION
Zero liquid discharge is a wastewater management
system that ensures that there will be no discharge
of industrial wastewater into the environment. It is
achieved by treating wastewater through recycling and
then recovery and reuse for industrial purpose. Hence ZLD
is a cycle of closed loop with no discharge.
26 z CHEMICAL NEWS MARCH 2020
Treatment of industrial wastewater has received
steadily increasing attention across the world. During
manufacturing, wastewater get generated at various
stages which are very complex in nature and highly
variable in quantity & quality. Unless & until we adopt a
structured approach towards collection, segregation &
treatment, it is difficult to achieve desired results.
There are several methods available for the treatment
of wastewater. These may be classified into two categories
: to meet the discharge norms and to meet the ZLD
norms. In this paper, we have done comparative techno-
economic feasibility study for 2.5 MLD capacity effluent
treatment plant (ETP) to meet the standard discharge
norms and to meet ZLD norms based on environmental
parameters considering power consumption, CO2
emission, solid waste generation and chemical
consumption and economic parameters considering
capital expenditure and operational expenditure.
2
METHODOLOGY
Wastewater quantity, characteristics & treatment
scheme are described below:
2.1 WASTEWATER QUANTITY & CHARACTERISTICS
The wastewater treatment plant capacity considered
in this case is 2.5 MLD. The untreated wastewater
characteristics and treated wastewater characteristics are
shown in Table 1.
2.2 EFFLUENT TREATMENT SCHEME TO MEET STANDARD
DISCHARGE NORMS
The effluent treatment scheme to meet standard
discharge norms is described below:
A. Primary Treatment: The primary treatment consists
of screening, equalization, neutralization, coagulation,
flash mixing, flocculation and primary clarification for
removal of suspended particles and some organic
impurities.
B. Secondary Treatment: The secondary treatment
consists of activated sludge process where effluent
will be received after primary treatment. In secondary
treatment biological process take place for removal of
organic impurities and further secondary clarification
for solid impurities removal.
C. Sludge Dewatering: The Sludge dewatering technology
 TABLE 1: UNTREATED WASTEWATER CHARACTERISTICS AND TREATED WASTEWATER CHARACTERISTICS
SR. NO. PARAMETERS UNIT UNTREATED WASTEWATER TREATED WASTEWATER CHARACTERISTICS
CHARACTERISTICS TO MEET DISCHARGE NORMS
1 PH - 1.5 to 11 6.5 to 7.5
2 COD mg/l 2000 to 5000 <250
3 BOD mg/l 500 to 2500 <100
4 Total Suspended Solids mg/l 50 to 300 <100
5 Total Dissolved Solids mg/l 2000 - 13500 NA
6 Oil and Grease mg/l Less than 10 <10
7 Ammoniacal Nitrogen mg/l 50 to 100 <50

will be implemented for removal of moisture / excess
water from sludge and collected water will be sent to
equalization tank for further treatment. The dried Cake
sludge will be sent to authorized land filling site for
disposal.
The treated effluent discharged into Sea/Estuary
directly or by CETP meeting the standard discharge
norms. The effluent treatment scheme to meet standard
discharge norms is given in Figure 1.
2.3 EFFLUENT TREATMENT SCHEME TO MEET ZERO
LIQUID DISCHARGE NORMS
The effluent treatment scheme to meet zero liquid
discharge norms is described below:
A. Primary Treatment: The primary treatment consists
of screening, equalization, neutralization, coagulation,
flash mixing, flocculation and primary clarification for
removal of suspended particles and some organic
impurities.
B. Secondary Treatment: The secondary treatment
consists of activated sludge process where effluent
will be received after primary treatment. In secondary
treatment biological process occurred for removal of
organic impurities and further secondary clarification
for solid impurities removal.
C. Sludge Dewatering: The Sludge dewatering technology
will be implemented for removal of moisture / excess
water from sludge and collected water will be sent to
equalization tank for further treatment. The dried Cake
sludge will be sent to authorized land filling site for
disposal.
D. Tertiary Treatment: The tertiary treatment consists of
removal of residual organic, TSS & backwash water by
Tertiary clarifier, Filter Media and further treatment by
UF & RO for maximum wastewater recycling then RO
reject will be sent to MEE and further ATFD to achieve
the Zero Liquid Discharge norms. Condensate from both
MEE & ATFD will be sent to Tertiary clarifier tank. RO

FIGURE – 1: PROCESS FLOW DIAGRAM FOR ETP TO MEET THE STANDARD DISCHARGE NORMS.

Incoming
Raw Effluent Primary
Equalisation Flash Mixing Flocculation
Clarification

Supernatant
Line

Sludge Sludge Holding Sludge

Dewatering Tank

Sludge for
Disposal

Treated Effluent Secondary Aeration

Discharge To CETP Clarification

Return Activated Sludge

CHEMICAL NEWS MARCH 2020 z 27

 FIGURE – 2: PROCESS FLOW DIAGRAM FOR ETP TO MEET ZLD NORMS
Incoming
Raw Effluent
Equalisation Flash Primary
Mixing Flocculation Clarification Aeration Secondary
Clarification

Supernatant Line

Sludge Circulation
Sludge Sludge Sludge Wasting
Sludge For Disposal
Dewatering Holdering Tank

Condensate & Back Wash Water Line Clarified

Water Tank

UF Filtered Water Tertiary

UF Systems ACF PSF
Permeate Tank Clarification
Tank

Back Wash Feed Line

Feed Flow
R.O
Reverse Osmosis (R.O) Permeate For Process Uses Back Wash
Tank
Permeate

MEE
RO Reject

Condensate Water
Salt For Disposal

TABLE 2: TECHNO-ECONOMIC FEASIBILITY STUDY OF 2.5 MLD ZLD PLANT.

PARAMETERS UNIT OF ETP TO MEET ETP TO MEET DIFFERENCE
MEASUREMENT DISCHARGE NORMS ZLD NORMS
Power Consumption KW/Day 7740 30760 4 times higher power consumption in ZLD
CO2 Emission Tons/Day 6.3 25.2 4 times higher CO2 emission in ZLD
Solid Waste Generation Tons/Day 30 61 2 times higher waste generation in ZLD
Chemical Consumption Kg/Day 1160 2626 2 times higher chemical consumption in ZLD
Capital Cost INR in Crore 40 100 2.5 times higher capital cost in ZLD
Operational Cost INR/KL 500 1500 3 times higher operating cost in ZLD

permeate will be used in Cooling tower & other Process. parameters we have considered power consumption,
The dried Salt solid waste will be sent to authorized land CO2 emission, solid waste generation and chemical
filling site for disposal. The effluent treatment scheme consumption.
to meet ZLD norms is given in Figure 2. z Economic Parameters : Under economic parameters

3
we have considered capital expenditure and
RESULTS AND DISCUSSION operational expenditure.
Techno-Economic feasibility study of zero liquid
discharge plant has been done based on following The results of our techno-economic evaluation to meet
parameters: discharge norms and to meet ZLD norms are tabulated
z Environmental Parameters : Under environmental under Table 2.

28 z CHEMICAL NEWS MARCH 2020

 FIGURE 3: ENVIRONMENTAL FEASIBILITY OF ZERO LIQUID DISCHARGE PLANT

Power Consumption Solid Waste Generation

35000 70
30760 61
30000 60
25000 50

TONS / DAY
KW / DAY

20000 40
30
15000 30
10000 7740 20
5000 10
0 0
ETP to meet Discharge norms ETP to meet ZLD norms ETP to meet Discharge norms ETP to meet ZLD norms

CO2 Emission Chemical Consumption

30 3000
25.2 2626
25 2500

20 2000
TONS / DAY

KG / DAY

15 1500
1160
10 1000
6.3
5 500

0 0
ETP to meet Discharge norms ETP to meet ZLD norms ETP to meet Discharge norms ETP to meet ZLD norms

3.1 ENVIRONMENTAL FEASIBILITY Paris agreement on climate change has identified

Under environmental feasibility, we have calculated the
power consumption, CO2 emission, solid waste generation
& chemical consumption. It has been found that power
consumption & CO2 emission to meet ZLD norms are 4
times higher than to meet the standard discharge norms.
It has been also found that solid waste generation &
chemical consumption to meet ZLD norms are 2 times
higher than to meet the standard discharge norms. Power
consumption, CO2 emission, solid waste generation and
chemical consumption to meet discharge norms as well as
to meet the ZLD norms are shown in Figure 3.
CO2 emissions as one of biggest root cause for
global warming hence this is responsibility of world
communities to reduce CO2 emissions. The concept
of establishment of ZLD may be good but it cannot be
generalized and implemented hastily and uniformly
over the entire country as it is emits more carbon
leading to global warming and generate huge amount of
hazardous solid waste occupying more land fill land.
3.2 ECONOMIC FEASIBILITY
Under economic feasibility, we have calculated the

Paris agreement on climate change has identified CO2 emissions as one of biggest
root cause for global warming hence this is responsibility of world communities
to reduce CO2 emissions. The concept of establishment of ZLD may be good but
it cannot be generalized and implemented hastily and uniformly over the entire
country as it is emits more carbon leading to global warming and generate huge
amount of hazardous solid waste occupying more land fill land.

CHEMICAL NEWS MARCH 2020 z 29

 FIGURE 4: ECONOMIC FEASIBILITY OF ZERO LIQUID DISCHARGE PLANT

Capital Cost Operational Cost

120 1600
1500
100 1400
100
1200
INR IN CRORES

80
1000

INR / KL
60 800
40 600
40 500
400
20 200

0 0
ETP to meet Discharge norms ETP to meet ZLD norms ETP to meet Discharge norms ETP to meet ZLD norms

capital cost & operational cost. It has been found that
capital cost to meet ZLD norms are 2.5 times higher than
to meet the standard discharge norms. It has been also
found that operational cost to meet ZLD norms are 3
times higher than to meet the standard discharge norms.
Capital cost and operational cost to meet discharge
norms as well as to meet the ZLD norms are shown in
Figure 4.
treatment plant to meet standard discharge norms
where Sea/Estuary discharge possible with below control
measures.
z Target to reduce the fresh water consumption
& effluent generation with latest sustainable
technologies.
z Implement effluent stream identification,
characterization & segregation at sources for better

4
SUMMARY AND CONCLUSION
Zero Liquid Discharge is not an environmental
friendly technique specially in costal area due to
following reasons:
z 4 times higher power consumption in ZLD.
z 4 times higher CO2 emission in ZLD.
z 2 times higher waste generation in ZLD.
z 2 times higher chemical consumption in ZLD.
z 2.5 times higher capital cost in ZLD.
z 3 times higher operating cost in ZLD.
Implementation of ETP to meet ZLD norms will
require more land which may not available with the
industry within premises or in the adjoining area. Each
state has its own uniqueness about its eco system and
the environment. The disposal of treated effluent inside
the Sea/Estuary is a better choice as huge dilution is
available and the impact on the marine eco system will
be minimum.
Considering above adverse impact of ZLD on
environment, it has been suggested to implement effluent
effluent management & treatment.
z Implement latest & advance technologies for
maximum recycling of treated wastewater to reduce
quantity of treated effluent discharge.
REFERENCES
1. American Public Health Association. 1985.Standard Methods for
the Examination of Wastewater (16th edition). APHA, AWWA, WPCE,
Washington, DC.
2. Birdi, G. S. and Birdi, J.S.. 1988. Water Supply and Sanitary
Engineering. Dhanpat Rai Publishing Company, New Delhi.
3. Chaubey, Mritunjay. 2002. Computer Design of Wastewater Treatment
Plant Using Fixed Film Bioreactor Technology. Journal of Industrial
Pollution Control, Vol. 18 (1), pp 107 – 117.
4. Chaubey, Mritunjay and Kaushika, N. D. 2003. Performance Analysis
of Fixed Film Bioreactor Plants For Wastewater Treatment. Journal of
Industrial Pollution Control, Vol.19 (2), pp.203 – 213.
5. Kaushika, N. D. and Chaubey, Mritunjay. 2002. Energy Efficiency in
Wastewater Treatment Plants. Environmental Pollution Control Journal .
6. Metcalf and Eddy. 1979. Wastewater Engineering. Tata Mc.Graw Hill,
New Delhi.
7. Rudolfs, W. 1953. Tndustrial Waste Treatment. Reinhold Publishing
Corp. , New York.

ABOUT THE AUTHOR: DR. MRITUNJAY CHAUBEY is sustainability, environment & water technology expert of international repute. He has done Ph.D.
in environmental engineering from Indian Institute of Technology (IIT) Delhi. He has nearly 23- years of professional working experience in renowned
MNCs Pentair, Shell, Unilever & UPL in field of sustainability, environmental engineering, water & wastewater treatment. Currently more than 100
environmental protection technologies are successfully working in Asia, Africa, Europe and America designed by him. More than 50 technical papers
has been published in renowned international journals & conferences with his name.
Dr. Chaubey is currently working as Global Vice President – Environment, Sustainability & Green Cell with UPL Limited. Recently Dr. Chaubey is awarded
with “Most Influential Sustainability Leader Award” and “CSO of the Year Award”.
E-mail : mritunjay.chaubey@upl-ltd.com

30 z CHEMICAL NEWS MARCH 2020