COVER STORY
Energy Efficient PT-RO & WHE System in
Industrial Wastewater System for ZLD
Market surveys and reports have pegged market opportunity of ZLD at around INR
2.7 billion in India (in 2017), in major water-intensive sectors, which is expected to
grow at 15-20% annually over the next five years.
By Rochem Separation System India (P) Ltd.
Zero Liquid Discharge
(ZLD) Background in India
Industrial wastewater treat-
ment scenario in India has
been very dynamic in wake
of Central Pollution Control
Board (CPCB) Guidelines for
Zero Liquid Discharge (ZLD)
for major water consuming
industries viz. Paper and Pulp,
Refineries, Textiles, Tanneries,
CETPs, etc.
This is a reaction to severe
pollution of water bodies and
acute water scarcity faced by
Nation to ensure reduction of
water consumption and appro-
priate treatment of industrial
wastewater.
Market surveys and reports
available on the digital media
have pegged market opportu-
nity of ZLD at around INR 2.7
billion in India (in 2017) in
major water-intensive sectors
which is expected to grow at
15-20% annually over the next
five years.
Historically, there was a re-
luctance to go for zero liquid
discharge by industries due to
24 October, 2018
high operating costs & lack of
reliable and efficient technolo-
gies in India.
However, the last decade has
seen that perception changing
mainly due to stricter regula-
tion by local pollution control
bodies & loss of production
due to water shortage or lack
of good quality of water.
The CETP structure has
been successfully implement-
ed in many industrial clusters
across India.
CETPs are then allowed to
discharge wastewater post
required treatment to water
bodies.
Recently it has been ob-
served that CETP run by par-
ticipating members have flout-
ed norms of discharge limits.
The strict action from National
Green Tribunal (NGT) and
the committee formed by Su-
preme Court of India has re-
sulted in the closure of many
such CETPs.
The closure of CETPs has
led to participating member
industries curtail or shut down
INDUSTRIAL WATER CASE STUDIES
operations due to lack of ZLD
systems installed which is the
requirement now. This uncer-
tainty has raised questions
about the reliability of CETPs
and industries have moved to-
wards ZLD to avoid dependen-
cy of CETP.
The guidelines issued by
CPCB in wastewater intensive
industries has further pushed
industries towards ZLD route
post-2016.
In this case study, we have
highlighted the energy-effi-
ciency of Rochem products
such as PT-RO and WHE for
ZLD in the industrial waste-
water.
With these energy-efficient
solutions, Rochem shall fur-
ther consolidate market leader
position in the next five years
in India.
In India, power generation
has been predominantly based
on fossil fuels, the energy effi-
ciency will bring down carbon
footprints to great extent with
increasing use of Rochem
solutions. High-Pressure
ROs (HP PT-RO)
The treatment of industrial
wastewater has always been a
problematic process, one that
involves multiple steps which
can often be labor and capi-
tal intensive. Even yet these
conventional processes fail to
consistently meet the new and
more stringent discharge stan-
dards.
Looking at the current water
scenario in the country and the
expected real valuation of the
cost of water soon, industrial
wastewater is fast becoming a
valuable alternate resource.
Rochem with its highly ef-
fective and efficient HP PT-RO
module membrane system
has answered the challenge
by treating wastewater direct-
ly into the reuse quality fresh
water.
The Rochem module con-
cept is based on the following
objectives and in-service re-
quirements:
SMART WATER & WASTE WORLD
o C rossflow supply of the un-
treated solution feed to the
membranes with the mem-
brane elements being hy-
draulically in series.
o Creation of extremely short
untreated solution flow
paths in the individual
membrane elements until
the final flow reversal.
o Creation of open duct over
the membrane surfaces for
the untreated soluti0n.
Advantages of Rochem PT-
RO Systems
o S implified pre-treatment
o Direct applications to high
COD/BOD, SDI, turbidity
streams
o No suspended solid fouling
o Consistent high quality per-
meates
o Single treatment and reuse
solution
HP PT-RO System
Case Study: AKR Fab
Industries Limited,
Perundurai, Tamilnadu
Scheme Before Installation of
Rochem PT (HP) - RO
o F eed Capacity: 250 m3/day
o Feed TDS: 75,000 ppm
Before installation of
Rochem PT (HP)-RO system
RO Rejects of 75,000 ppm
were being fed to MEE to at-
tain ZLD. By incorporating
COVER STORY
Existing Scheme
Rochem PT (HP)-RO, the load
on MEE is reduced by 35%
thus reducing steam consump-
tion for MEE significantly. The
total steam savings because of
this is 21.9 ton/day. The pow-
er consumption remains the
same for both the options.
Waste Heat
Evaporator (WHE)
Waste Heat Evaporator
based on Membrane Distilla-
tion is a process that utilizes
differences in vapor pressure
to permeate water through a
hydrophobic membrane and
reject other non-volatile con-
stituents present in the feed.
Waste Heat Evaporator
works in an uncomplicated
manner. The entire process can
be summarized in four critical
steps.
These are:
WHE Installed Plant of Capacity 10 m3/day
SMART WATER & WASTE WORLD
Step 1: H
 eat is transferred
from the bulk fluid to
the wastewater surface.
Step 2: Wastewater evaporates
from the surface.
Step 3: 
Wastewater vapor dif-
fuses through the mem-
brane.
Step 4: Wastewater vapor con-
denses on the other
side of the membrane.
Advantages
o Separation of the volatile
component from solutions
o The concentration of the
aqueous solution to produce
fresh water from highly con-
centrated feeds
o Compact and modular de-
sign
o Low life cycle cost
o Safe operations at a low tem-
perature
o Lower electrical energy con-
sumption
o Ease of maintenance as the
system is skid mounted at
ground level
o Limits scaling and corrosion
issues
o High-quality of distillate
o Reduction in non-condens-
able species in the vapor
phase
INDUSTRIAL WATER CASE STUDIES
Waste Heat Evaporator
System (WHE) Case
Study: AKR FAB Industries
Ltd, Perundurai
o F
 eed Capacity: 36 m3/day
o F
 eed TDS: 1,50,000 ppm
By choosing to opt for such
studies illustrated earlier that
the introduction of Rochem’s
ROCHEM HP PT-RO
Industrial wastewater is
a scheme, our client has saved innovative solution for evap- fast becoming a valuable
20 ton/day steam equivalent
energy.
oration has very low energy
footprint (both electrical &
alternate resource. Rochem
with its highly effective and
The WHE system utilizes thermal) compared to conven- efficient HP PT-RO module
membrane system has an-
swered the challenge by treat-
ing wastewater directly into
the reuse quality fresh water.
ATFD vapors for evapora-
tion instead of steam from
WHE Installed at J&J, Hyderabad
the boiler. Hence, the client
was not required to spare any
steam. This also has created
additional capacity in existing
MEE for future expansion if
required. This has saved Opex
and Capex as available ATFD
vapors were utilized.
Conclusion
Based on the estimates from
the market it is reported that
Multiple Effect Evaporator
(MEE) business for Zero Liq-
uid Discharge (ZLD) is grow-
ing at 20% CAGR. tional evaporation systems.
IN A NUTSHELL
Industry: Textile
Customer: AKR Fab Indus-
tries Limited
Location: Perundurai, Tamil
Nadu
Service Provider: Rochem
Separation System India
Every year approximately The projections for growth of Products/Technology In-
20,000 m3 equivalent capac- Rochem Waste Heat Evapora- volved: Zero Liquid Dis-
ities Evaporators are being tor (WHE) sales in ZLD market charge (ZLD), PT-RO Systems,
sold. The projections based on and its impact on energy foot- Waste Heat Evaporator Sys-
above are tabulated as below. print is tabulated as below. tems (WHE)
As it is evident from case
October, 2018 25