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Reuse Wastewater Generated by the Paint and Textile Manufacturing Industries in the Manufacture of Cement Bricks and Tiles:
Case Studies from Egypt
Alabama Water resources Conference; Orange Beach, Alabama, September 5 - 7, 2012
Dr. Robert W. Peters.
Professor of Environmental Engineering
University of Alabama at Birmingham, Birmingham, Alabama
Eng.Mohamed Khaled Elsayed Mostafa
Ph.D. Graduate Student
University of Alabama at Birmingham, Birmingham, Alabama
by
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Statement of scientific or technical problem
Overview
Introduction
Primary objective of the research
Reusing wastewater
Conclusion
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Statement of scientific or technical problem
1- Discharge of industrial effluents into surface water body without prior treatment;
2- The use of old technologies and non-biodegradable substances in industrial processes;
● Poor quality of surface water in Egypt
►Some factors impacting this problem:
(Source: www.inmagine.com, 2011)
Mediterranean Sea
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Introduction
(Source: National Research Centre, 2007 )
0
50
100
150
200
250
Chemicals Food Textiles Engineering Mining Metal sectors Other
Amou
nt (M
m3 /
yr)
Industrial Sector
Amount of wastewater produced from various industrial sectors
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Introduction
0
50
100
150
200
250
300
350
400
450
BOD COD Oil and Grease TDS Heavy Metals
Lo
ad
(t/
d)
Contaminant
(Source: National Research Centre, 2007)
The loads of the most common contaminants contained within sewage
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Primary objective of the research
● Study potential reuse of wastewater generated by the paint and textile manufacturing industries.
DYEING PRINTING FINISHINGPRE-TREATMENT
DYE WASTEWATER
Paint industry
Textile industry
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ParameterResults (ppm)
ParameterResults (ppm)
Cadmium (Cd) < 0.01 Magnesium (Mg) 5.0Cobalt (Co) 0.03 Sodium (Na) 25.6Nickel (Ni) < 0.01 Potassium (K) 0.3Lead (Pb) < 0.01 Chlorine (Cl) 22.5
Iron (Fe) 0.01Total Dissolved Solids
(TDS)4,576
Zinc (Zn) 0.05 PH (unitless) 9.58
Manganese (Mn) 0.04 Phosphor (p) 0.56
Copper (Cu) 0.07 Calcium (Ca) 11.5
Nitrogen (N) 29.4
Analysis of a typical paint wastewater sample
Reusing wastewater
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Analysis of a typical dye wastewater sample
Reusing wastewater (cont’d)
ParameterResults (mg/l)
ParameterResults (mg/l)
Total Dissolved Solids (TDS)
18,165 Chlorine (Cl) 13,270
Total Suspended Solids (TSS)
1,572 Oil and grease 37.6
Chemical Oxygen Demand (COD)
943.0 Total Phosphate 5.2
Biological Oxygen Demand (BOD)
203.0 Organic nitrogen 21.0
PH (unitless) 10.12 Nitrate (NO3-) 5.0
Sulphur trioxide (SO3) 311.0 Nitrite (NO2-) 20 .0
Ammonia (NH3) 6.8
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Reusing wastewater (cont’d)
Statistical Market Forecast for Concrete Blocks and Tiles in Egypt
(Source: Gobi International, 2009 )
2005 2006 2007 2008 2009 2010 2011 2012 2013 20140
5
10
15
20
25
30
Year
US
Dol
lars
mil
lion
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Cement bricks
Mix proportions of the cement bricks
Reusing wastewater (cont’d)
Brick: 25*12*6 cm
Raw Material/Mixture No.
A (Clean water)
B (Paint WW)
C (Dye WW)
Coarse aggregate (m3) 0.9 0.9 0.9
Clean water (L) 288 N/A N/A Wastewater (L) N/A 288 225
Cement (kg) 400 400 400Fine aggregate (m3) 0.9 0.9 0.9
BVF (kg) 1.2 1.2 1.2
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● Compressive Strength: (Sample: 25*12*6 cm)
► Minimum compressive strength value specified in ASTM C 55-06 equal 13.8 Mpa (140 kg/cm2).
Reusing wastewater (cont’d)
Mix Sample Number Max. Stress (kg/cm²) 1 175
A (Clean water) 2 170 3 181 Average 175 1 172
B (Paint wastewater) 2 176 3 166 Average 171 1 168
C (Dye wastewater) 2 174 3 180 Average 174
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● Water Absorption:The water absorption testing results
► Maximum water absorption value specified in ASTM C 55-06 equal 240 kg/m3.
Reusing wastewater (cont’d)
Mix Sample Number Water absorption (kg/m³) 1 225
A (Clean water) 2 230 3 229 Average 228 1 212
B (Paint Wastewater) 2 215 3 216 Average 214 1 206
C (Dye Wastewater) 2 208 3 209
Average 208
● Toxicity Characteristic Leaching Procedure (TCLP) Test:
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TCLP test results of the bricks
Reusing wastewater (cont’d)
Paint WW Dye WW Metals (mg/L) (mg/L) EPA limit (mg/L)
Arsenic (As) ˂ 5.0 ˂ 5.0 5.0Cadmium (Cd) ˂ 0.05 ˂ 0.05 1.0
Chromium Cr(total) 0.22 1.3 5.0Copper (Cu) 0.007 2.8 15.0
Mercury (Hg) ˂ 0.001 0.06 0.2Lead (Pb) ˂ 0.1 1.2 5.0Zinc (Zn) ˂ 0.03 4.2 25.0Iron (Fe) ˂ 0.05 3.5 5.0
Nickel (Ni) 0.079 2.5 7.0Chloroform (CHCl3) ˂ 5.0 2.1 6.0
Chlorobenzene ˂ 5.0 20 100
● Sulfide and Cyanides:
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● Ignitability and Corrosivity:
Reusing wastewater (cont’d)
Mix Sulfide, (mg/kg) Cyanides, (mg/kg)
B (Paint wastewater) 1.52 ˂ 1.0
C (Dye wastewater) 4.50 ˂ 1.0
EPA limit 500 250
Mix Ignitability, °C (°F) Corrosivity, pH
B (Paint wastewater) 100°C (212°F) 10.0
C (Dye wastewater) 110°C (230°F) 11.2
EPA limit Less than 60°C (140°F) (corrosive)pH < 2 or > 12.5
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Cement tiles
The mix proportions to produce 6 m2 tiles
Reusing wastewater (cont’d)
Tile: 30*30*2 cmRaw
Material/Mixture No. A
(Clean water) B
(Paint WW)C
(Dye WW) Coarse aggregate (kg) 120.0 120.0 120.0
Clean water (L) 15.0 N/A N/A Wastewater (L) N/A 15.0 15.0
Cement (kg) 50.0 50.0 50.0Fine aggregate (kg) 70.0 70.0 70.0
BVF (litter) 1.0 1.0 1.0
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● Compressive Strength: (Sample: 15*15*15 cm):Arduous service
Compressive strength of the tiles after 28 days
Reusing wastewater (cont’d)
Mix Sample Number Max. Stress (kg/cm²) 1 701
A (Clean water) 2 736 3 671 Average 702 1 688
B (Paint WW) 2 680 3 685 Average 684 1 700
C (Dye WW) 2 693 3 691
Average 695
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Bending strength of the tiles after 28 days
● Bending Strength: (Sample: 30*10*2.0 cm): Arduous service
Reusing wastewater (cont’d)
Mix Sample Number Max. Stress (kg/cm²) 1 88.7
A (Clean water) 2 89.2 3 93.85 Average 89.93 1 95.54
B (Paint WW) 2 95.7 3 93.48 Average 94.61 1 95.4
C (Dye WW) 2 96.5 3 93.2 Average 96.12
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The water absorption testing results of the tiles
● Water Absorption: must not exceed the 8% maximum percentage specified in E.S.S 269-2005.
Reusing wastewater (cont’d)
Mix Sample Number % 1 4.44
A (Clean water) 2 4.57 3 4.7
Average 4.57 1 4.56
B (Paint WW) 2 4.55 3 4.22
Average 4.44 1 4.41
C (Dye WW) 2 4.15 3 4.2
Average 4.25
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● Toxicity Characteristic Leaching Procedure (TCLP) Test:
TCLP test results of the tiles
Reusing wastewater (cont’d)
Paint WW Dye WW
Metals Conc. (mg/l) Conc. (mg/l) EPA Limits (mg/l)
Nickel (Ni) ˂ 0.05 0.6 7.0
Cadmium (Cd) ˂ 0.05 ˂ 0.05 1.0
Copper (Cu) 0.005 0.1 15.0
Chromium Cr(total) 0.3 0.5 5.0
Lead (Pb) ˂ 0.1 ˂ 1.0 5.0
Zinc (Zn) ˂ 0.05 2.0 25.0
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● Abrasion resistance: (Sample 30*30*2 cm): Arduous service
The abrasion testing results of the tiles
Reusing wastewater (cont’d)
Mix Sample Number Loss in thickness, mm 1 0.91 A (Clean water) 2 0.71
3 0.70 Average 0.75 1 0.93
B (Paint WW) 2 0.97 3 0.97 Average 0.97 1 0.82
C (Dye WW) 2 0.79 3 0.84 Average 0.81
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Recommendation● Construct a unit to produce the cement bricks and tiles near to
the wastewater stream.
Egg-laying machine
Concrete mixer
Tile machine
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Conclusion
● Reuse wastewater generated by the paint and textile manufacturing industries.
The monthly volumes of wastewater going for treatment (wastewater from washing and cleaning the tanks)
0
10000
20000
30000
40000
Month-year
Vol
um
e(G
allo
n)
(Source: with permission from CMB Company, Egypt)
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Conclusion (cont’d)
Different shapes of cement bricks Different shapes of cement tiles
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Questions?