WASTEWATER TREATMENT & REUSE

PILOT TEST FOR WASTEWATER TREATMENT CONCEPT AT

SHAMPOO
MANUFACTURING FACILITY
Based on test
results, DAF-
Floatation is
selected as best
pre-treatment
followed by MBBR
technology and
DAF as secondary
clarification to
remove rest of the
By Dibyendu Goswami COD and detergents
efficiently.

Cosmetic production industry is strictly adhere to
the water quality standards throughout the entire
process of product manufacturing in order to meet
the product water quality in terms of hygienic
requirement.
The factory at present now produces hair, skin care
Fast Facts
Project for: Unilever
Work Includes: To assist the
selection of correct technology for
wastewater treatment plant
Result: Reduction of COD and
anionic detergents up-to 97%-99%
and household cleaning products, for worldwide
distribution on highest scale, so why wastewater
treatment of such kind of effluent from process,
utility is on higher priority to meet very stringent
norms of BOD, COD, anionic detergents, nitrogen
as per local pollution control board.
The Challenge
Unilever is facing very hard challenge to formularize
the concept of putting complete wastewater
treatment plant in terms of capital cost investment
as well as availability of area within the plant.
Initially some of core technology have been taken
into idea such as activated sludge, SBR, MBR
and combination of physio-chemical treatment
to fit the area and both capital and operation
cost but from the assessment nothing looks very
convincing in terms of construction within limited
space (27 m x 14 m) and investment point of view.
The Solution
To assist in the selection of the correct technology,
several laboratory trials and pilot trials have been
suggested and agreed.
Flocculation-floatation with DAF
Flocculation-sedimentation
Evaporation
The test wastewater used for the trials consisted of
samples direct from the concentrated wastewater
stream mainly composition from shampoo,
conditioner and body lotion product.
Evaporation trial produced results with the
highest percentage COD reduction and anionic

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

 Keywords: Wastewater Treatment Plant, Flocculation-Floatation, Flocculation-Sedimentation, Evaporation

detergent removal, however performance was

found inconsistent and unreliable. Issues were
encountered with excessive foam generation in a
number of the samples, often bringing cause to
a premature stop of the evaporation process and
contamination of the distillate.

Flocculation-sedimentation were reported to

produce more consistent results, however most
samples fell short of meeting discharge consent
criteria, including the majority of results for critical anionic flocculant 12 mg/l After Preliminary Tests with Coagulants
parameters, COD, anionic detergents, and total PAX XL19F dose of 9 ml / l, pH = 7.5, the Rejected: Aluminum sulfate, ferric chloride - due
nitrogen. anionic flocculant 10 mg/l to very high doses necessary to achieve the effect
of coagulation (very high salinity of the effluent
It follows on basis of these trials that a second Parameter 0 1 2 3 4 from the treatment of disqualifying).
stage biological treatment may be necessary to COD 13500 2500 1300 1750 1950
achieve final discharge consent criteria. Sample - II: Comparison of the effect of treatment
BOD 6000 970 950 1100 1200
with the use of selected coagulants at optimal
Anionic
Lab Test Methodology Detergent
4500 650 500 550 600 doses - coagulation + DAF-floatation with 100%
and 200% recirculation:
Selection of Coagulant - Coagulation Tests The best performance was achieved with Al.3010,
with Sedimentation Al.1019. Despite the relatively high optimal doses coagulation + flotation Al3010, recirculation
In preliminary studies, which results due to the - the resulting salinity of wastewater measured - 200%, a dose of 3 ml/l, pH = 7.5, anionic
large amount of test work are not presented in as chloride is much below the permissible value flocculant 10 mg/l
this report, the following coagulants were verified: of 1000 mg Cl/l. The results shown in Tables 1 and coagulation + flotation Al3010, recirculation
2 - the effect of treatment, indicate that classical, - 100%, a dose of 3 ml/l, pH = 7.5, anionic
Brenntafloc Al.3010 - a complex solution usually an effective coagulant, PAX 16 gives a flocculant 10 mg/l
aluminium polyhydrochloride much worse effect of the reduction of COD and coagulation + flotation Al1019, recirculation
Brenntafloc Al.1019 - polyaluminium anionic detergents, while the dose is so high (at a - 200%, a dose of 3 ml/l, pH = 7.5, anionic
chloride solution, typical wastewater composition is about 18 dm3/ flocculant 10 mg/l
Brenntafloc F3 - Ferric chloride solution, m3) that the concentration of chlorides remaining coagulation + flotation Al1019, recirculation
PAX16 - aluminium polychloride after treatment is several times higher than - 100%, a dose of 3 ml/l, pH = 7.5 anionic
PAX XL19F - pentahydroxy aluminium acceptable. flocculant 10 mg/l
chloride
Aluminum sulfate - 25% solution,

Sample - I: Comparison of the effect of treatment

with the use of selected coagulants at optimal
doses - coagulation + sedimentation:

Al3010 dose of 6 ml / l, pH = 7.5, the anionic

flocculant 10 mg/l
Al1019 dose of 6 ml / l, pH = 7.5, the anionic
flocculant 10 mg/l
PAX 16 dose of 18 ml / l, pH = 7.0, the

The pilot test provided a correct solution

for the plant. The plant is running very
smoothly since its execution in December
2015, and providing highest level of
purification of organics and detergents.
Cylinders from the Left: After Flotation Time of 1 Hour
Sample II Flotation, the Coagulant Al3010 (Without Recirculation)
Sample II Flotation, the Coagulant Al3010 - Recirculation 1 + 1
Sample II Flotation, the Coagulant Al3010 - Recirculation 1 + 2

www.eawater.com/eMagazine December 2016 | EverythingAboutWater 17

WASTEWATER TREATMENT & REUSE

Performance Results of Wastewater Treatment Plant

Parameter 0 1 2 3 4 Technology
As per results, DAF-Floatation is selected as best pre-treatment followed by
COD 13500 1721 3251 1530 2295
MBBR technology and DAF as secondary clarification to remove rest of the
BOD 6000 500 900 520 750 COD and detergents efficiently to meet the outlet discharge norms of COD <
Anionic detergent 4500 500 550 1000 500 700 mg/l, BOD < 500 mg/l, anionic detergents <15 mg/l. Only DAF and sludge
dewatering facility are new installation. Existing RCC tank is converted into
single stage MBBR with higher COD loading rate to fit the size and achieving
highest level of purification of organics and detergents as well. This plant
is executed and commissioned December 2015 and running very smoothly.

Performance Advantages

Consistent outlet water quality achieved

Close control over operation cost of chemical/sludge/power
Much simpler operation of MBBR technology
Higher sludge consistency (4%-5%)
Reduction of COD and anionic detergents up-to 97%-99%

About the Author

Dibyendu Goswami is Water & Wastewater Technologist with 9 years of
domestic and international water and wastewater experience in Leadership
Management, Technology & Proposals, Design and Engineering, Business
Development, Client Interaction, Networking, Strategy and Budgeting.
Dibyendu Goswami works as an International Water and Wastewater
Process Expert for Projects in Water Treatment Plant (WTP), Sewage
Treatment Plant (STP) and Effluent Treatment Plant (ETP). He has worked
for leading water & wastewater companies like Ion Exchange, M.N.Dastur
in India.

To know more about the author 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.

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