WASTEWATER TREATMENT & REUSE

UF AND RO FOR RECOVERY AND REUSE OF WASTEWATER IN

SUPERCRITICAL THERMAL
POWER PROJECT
Overview of design
philosophy of UF and
RO membranes based
system as envisaged
by Development
Consultants Private
Limited for reuse
of wastewater in
Supercritical Super
Thermal Power Project
By Bhaskar Sengupta
is discussed in this
case study.

Reuse of wastewater in power stations is
becoming increasingly important in many areas
around the world. Water scarcity, local regulations
and environmental impact are driving power
stations to reuse the large volume of wastewater
they produce. The selection of wastewater
treatment process is challenging as the liquid
effluents in power stations typically contain high
levels of salinity and their composition can vary
significantly. In recent years there has been a
growing interest in the integration of ultrafiltration
(UF) and reverse osmosis (RO) membrane
technologies for wastewater treatment and reuse.
In this case study, an overview of the design
philosophy of ultrafiltration and RO membranes
based system as envisaged by Development
Consultants Private Limited (DCPL) for reuse of
wastewater in a Supercritical Super Thermal
Power Project is discussed. The design approach
adopted by DCPL for an integrated membrane
system for treatment and reuse of wastewater in
a 2 x 660 MW Supercritical Super Thermal Power
Project in India has been demonstrated.
Introduction
Recovery and reuse of wastewater in power
stations is an issue of growing concern around
the world. Water scarcity, local regulations and
environmental impact are driving power stations
to reuse the large volume of wastewater they
produce. Such reuse can both contribute to
conservation of water resources and help meeting
strict environmental regulations regarding
discharge of liquid effluents. www.dcpl.net.in
The selection of wastewater treatment process is
challenging as the liquid effluents typically contain
high levels of salinity and their composition can
vary significantly. In recent years there has been a
growing interest in the integration of Ultrafiltration
(UF) and Reverse Osmosis (RO) membrane
technologies for wastewater treatment and reuse.
In this study, an overview of the design philosophy
of UF and RO membranes based system as
envisaged by DCPL for reuse of wastewater in
2 x 660 MW Supercritical Jaypee Nigrie Super
Thermal Power Project of Jaiprakash Power
Ventures Limited (JPVL) is furnished.
Fast Facts
Project: CMB Wastewater
Treatment
Requirement: To design WTP plant
to recycle 100% of treated effluent
Technology Used: Wastewater
Recovery System which includes
UF and RO Skids

94 December 2016 | EverythingAboutWater www.eawater.com/eMagazine

 Keywords: Ultrafiltration, Reverse Osmosis, Wastewater Reuse

Figure 1: Recovery Scenario with Wastewater Recovery System under Normal Operation.

Main Challenges for Treatment and
Reuse of Wastewater
The main challenges involved are as follows:
High level of salinity
High concentration of reactive silica and
other contaminants
The wastewater recovery system with RO
skids and UF skids, at design recovery
enables the power station to achieve
zero discharge is--vis conservation
of water resources and help meeting
strict environmental regulations regarding
discharge of liquid effluents.
For this project, both DCPL as well as JPVL
were very keen and committed to develop and
design the wastewater treatment system thereof
adopting the philosophy of 100% recycling of
treated effluent to implement Zero Discharge
concept.
The selection of wastewater treatment process
has been very challenging as the liquid effluents
typically contain high levels of salinity and their
composition can vary significantly. Further rates of
generation of few wastes are on continuous mode
where the others are not.
A detail study on profile of several variable
parameters examined by Consultant and finally
design analysis for treatment systems was arrived.
The design analysis as worked out and adopted
for CMB wastewater is furnished in Table 1.
Selection of Proper Sequence of
Pretreatment Steps
The wastewater streams from different sources
of 2 x 660 MW unit power stations are collected,
treated and then reused within the plant. Various
wastewaters, which are handled and treated for
reuse, are described hereinafter:
Cooling Tower Blow Down
As per the standard practice, the cooling tower
blow-down (CTBD) is done to maintain the level
of dissolved solids in the circulating cooling

www.eawater.com/eMagazine December 2016 | EverythingAboutWater 95

 WASTEWATER TREATMENT & REUSE

Design Analysis of CMB Waste Water Wastewater from Regeneration of solution is injected through NaOCl Dosing Pumps
Feed water Condensate Polishing Units (CPU) at backwash inlet line and Bisulfite solution is
Parameters Unit as Remarks
as such and Wastewater from Chemical injected by Sodium Bisulfite Dosing Pumps to
CaCO3
Physical parameters
Cleaning of Boilers neutralize residual NaOCl solution in UF module.
1 pH - 7.78 - Wastewater from CPU regeneration system and Plant Service Air is used for air scouring of the UF
2 Temperature C 35 max. - chemical cleaning of Boilers is collected in a units.
3 Turbidity NTU - - separate Neutralization Pit and further transferred
4 TSS mg/I 50 - to inlet of CMB by separate set of neutralized Permeate from UF Modules is stored in UF
5 TDS (Given) mg/I - - effluent disposal pumps. The tentative rate of Permeate Storage Tank.
6 TDS (Calculated) mg/I 1755 - transfer of waste is around 50 m3/hr.
Chemicals parameters The cleaning system is duly provided and it is
A Cation Wastewater Pre-Treatment System anticipated that cleaning is carried out every six
1 Calcium ppm 148.70 371 All liquid effluents are led to CMB (with two months. The cleaning system enables to maximize
2 Magnesium ppm 31.60 130
compartments), which acts as an equalization the membrane efficiency in the long run.
3 Sodium ppm 368.0 130
basin. Each compartment of the CMB has effective
4 Potassium ppm 0.0 0
volume equivalent to 12 hours detention period From UF Permeate Storage Tank, RO Feed Pumps
5 Dissolved iron ppm 0.64 1
6 Hydrogen (FMA) ppm 0.0 0 calculated based on average hourly flow with due transfer the UF Permeate through Micron Fillers
7 Copper ppm 0.64 1 consideration of all effluents. and then RO High Pressure Pumps boost the
8 Ammonium ppm 5.78 16 pressure of the water to feed it to RO pressure
Total Cation ppm - 1325 From CMB, wastewater is pumped by means vessels.
Total hardness ppm - 501 of a set of CMB waste transfer pumps to a
B Anion pretreatment system which includes a set of Various chemicals such as Hydrochloric Acid (HCl),
1 P-Alkalinity ppm - 0 high rate solid contact clarifiers for removal of Antiscalant and Sodium Bisulphite are dosed prior
2 M-Alkalinity ppm 108 suspended solids. The clarified wastewater from to RO Micron Fillers so as to optimize the water
3 Bicarbonates ppm 108 high rate solid contact clarifiers is stored in a Clear parameters before feeding to RO membranes.
4 Carbonates ppm 0 Water Reservoir for further treatment.
5 Hydroxides ppm 0
Conductivity Analyzer, ORP Analyzer and pH
6 Sulphate ppm 370
The sludge generated from high rate solid contact Analyzer are provided downstream of the Micron
7 Chlorides ppm 840
clarifiers as addressed above is collected in a Fillers to control of chemical dosing rates.
8 Nitrates ppm 0
9 Phosphate ppm 0 common sludge sump and finally pumped by The treated water from RO Skid is further treated
10 Flourides ppm 0 sludge disposal pumps to a sump for further by alkali for control of pH and then stored in RO
11 HSiO3 ppm 7.00 disposal to ash pond. Permeate Storage Tank.
Total Anion ppm 1325
EMA 1217 System Description of Wastewater Chemical cleaning and flushing system is provided
C Others Recovery System in order to maximize membrane efficiency in the
1 Reactive Silica ppm 112.97 94.00 The clarified water from the clear water reservoir long run. It is anticipated that cleaning will be
2 CO2 ppm 3.56 8.10 is used as input water for the wastewater recovery carried out every three to four months.
system.
water. This effluent contains dissolved solids and Reject from UF and RO Modules will be collected
chemicals/biocides used for prevention of scale Clarified water is pumped from clear water in UF and RO Reject Collection Sump.
formation/corrosion/bio fouling. CTBD is directed reservoir by a set of pumps to a battery of dual
to a Central Monitoring Basin (CMB). The tentative media filters for removal of residual suspended The effluents generated due to the Chemical
rate of CTBD is around 616 m3/hr. solids. From the Dual Media Filters, water flows Cleaning of UF Modules/RO Membranes will be
through Micron Filters to UF modules. disposed to the UF and RO Reject Collection Sump
Wastewater from Neutralization Pit to deliver the waste to the Ash Water Sump by UF
of DM Plant Ultra Filtration (UF) Modules is typically & RO Reject Transfer Pumps.
Wastewater from DM plant and UF units (envisaged backwashed once in every 30 minutes.
for removal of colloidal silica) is collected in the Backwashing of the UF modules is done using UF Selection of Design Parameters for
Neutralization Pit and further transferred to inlet permeate by using UF Backwash Pump. Wastewater Recovery System
of CMB by Neutralized Effluent Disposal Pumps. DCPL made rigorous study along with computer
The tentative rate of transfer of waste is around Maintenance cleaning of UF modules is done simulations by use UF System and RO System
300 m3/hr. once every day and Sodium Hypochlorite (NaOCl) Analysis Software as published by several

96 December 2016 | EverythingAboutWater www.eawater.com/eMagazine


membrane manufacturers to finalize the number
of treatment streams, percentage recovery, quality
of treated water etc. with reference to the target
of zero discharge, feasibility of reuse of treated
wastewater at different points of uses within the
Station as well as the overall economics.
Based on outcome of study, the Wastewater
Recovery System includes UF Skids and RO Skids:
Design Parameters set for UF Skids
System Recovery shall not be less than 90%.
Each skid has been designed for not less
than 4835 m3/day permeate flow.
Design Parameters set for RO Skids
System Recovery shall not be less than 80%.
Each Skid has been designed for not less
than 165 m3/hr of permeate flow.
TDS in RO permeate shall be not more than
120 ppm and pH of permeate shall 7.5.
With Wastewater Recovery System under normal
Simple design
Easy operation
Lowest cost permeate
enough said.
FEDCO offers a wide range
of high pressure pumps
(10 to 1800 m3/h) and
energy recovery turbocharger
devices (5 to 4000 m3/h)
from small to mega scale plants.
Singapore Office Dubai Office
+65.6779.0123 +971.04.880.7344
www.fedco-usa.com
www.eawater.com/eMagazine
Keywords: Ultrafiltration, Reverse Osmosis, Wastewater Reuse
operation, the recovery scenario is addressed in UF skids, at design recovery enables the power
Figure 1. station to achieve zero discharge is--vis
conservation of water resources and help meeting
To conclude, it will be worth mentioning that the strict environmental regulations regarding
wastewater recovery system with RO skids and discharge of liquid effluents.
About the Author
Bhaskar Sengupta has received the B.E. degree and M.E. degree (Gold Medalist) in Chemical Engineering
from Jadavpur University. He holds the position of Deputy General Manager and Engineering Manager (Water
Treatment Group) at Development Consultants Private Limited, Kolkata, India. He has More than 31 years of
experience in the field of Water and Wastewater Treatment Engineering. He has executed assignments for
projects in various sectors like Urban, Power, Paper, Defence, Cement, Fertilisers & Chemicals, Refineries
and Petrochemicals.
Development Consultants (DC) founded in 1950, when Dr. Sadhan C. Dutt, a young engineer from a Premier
Institute, gathered around him a team of brilliant engineers and launched the Indian operations of The Kuljian
Corporation (TKC) of USA, pioneering stand-alone consulting engineering firm in India. It coincided with
post-independence quest for an industrial future of the country.
To know more about the author and contributor of this case study, you can write to us. Your feedback is
welcome and should be sent at: mayur@eawater.com. Selected responses will get a 1-year complimentary
subscription of EverythingAboutWater Magazine.
Tel: +734.241.3935 sales@fedco-usa.com
Fluid Equipment Development Company, LLC
800 Ternes Drive, Monroe, MI 48162 USA
December 2016 | EverythingAboutWater 97