 "Case Study: ZLD technology gives a new lease of life to dyeing units in Tirupur")
Tirupur, which generates a fifth of India's textile exports, is known as a textile hub of the country. Garment units in Tirupur went through a crisis following the discharge of coloured effluents from bleaching and dyeing units that resulted in severe pollution of water bodies.
The challenge
Following the orders of the Madras High Court, more than 600 bleaching and dyeing units in Tirupur remained closed for almost two years for want of a reliable solution. The court observed that the dyeing units were polluting the river and could not function until zero discharge was achieved.
Textile industry generates high-volumes of wastewater containing various chemical used in dyeing, printing and finishing processes. Since, effluents of dyeing units are highly polluted and dangerous, they have to be treated with right technologies to nullify its harmful effect on the environment. Since characteristics of effluents varies with the type of raw materials used in the dyeing process, adopting right wastewater treatment technology is a challenge.
Though various technologies were implemented at Tirupur, none could solve the groundwater pollution problem effectively. This extended the closure of textile dyeing clusters till the installation of the Zero Liquid Discharge (ZLD) unit by Pune-based Praj Industries which has helped to build confidence for reopening of the textile units in compliance with the pollution norms.
Solution offered by Praj
Praj is one of the leading global players offering innovative solutions to significantly add value in water and wastewater treatment plants, bio-ethanol, bio-diesel, and brewery. Building on its expertise, Praj’s ZLD system, which is energy efficient with proprietary evaporation technology, caters to the various industrial process effluents such as RO reject, complex effluents, cooling tower blow down, etc. The entire basket of technology is available with Praj which forms an integrated part of ZLD system including pre-treatment, biological treatment, tertiary treatment, reverse osmosis, evaporation, crystallisation etc. Praj’s constant focus is always on recycle and reuse of water with its value added technologies.
Praj successfully commissioned a 100-kilo litre per day (KLD) ZLD plant at Veerapandi Common Effluent Treatment Plant (CETP), Tirupur. Praj supplied ZLD technology based on multi-effect evaporation system for textile CETP. The entire plant was designed, engineered, fabricated, erected and commissioned by Praj on turnkey basis.
The final end products are process condensate and salts which are of reusable quality. The reject of existing RO system is first preheated and then fed to the evaporation system in forward feed manner. Praj provided special proprietary designed forced circulation evaporator system. This unique technology is instrumental in solving the groundwater pollution problems arising due to discharge of colorants.
Praj ECOVAP system is suitable for operating at higher solid concentration & viscosity. Suspended solid slurry and precipitating salts can be handled by this system with no chocking issues and with less cleaning cycles.
In order to arrive the most appropriate solution, Praj deployed the best resources and efforts. This involved periodic collection and testing of effluent samples, study of existing effluent treatment plants, developing customised processes & engineering solutions and demonstrating the efficacy of the solution of the first plant at Veerapandi.
Growing together
Based on the successful operation of the first plant at Veerapandi CETP, Praj contracted a second order for treating 700-KLD of effluent from the textile dyeing cluster in 2012-13.
Praj later bagged the order from Sirupooluvapatti CETP for treatment of 5000 KLD of effluent, making it the largest installation. It consists of 3 stage treatment including the ZLD system based on multi effect evaporation. “Our ZLD system is energy efficient with low maintenance cost and operates for a longer period between cleaning cycles. The salts recovered from the CETP plant are being re-used by the dyeing units, resulting into considerable savings in operating cost, annually,” opined Pramod Chaudhari, Executive Chairman, Praj Industries.
| Snapshot Customer: Veerapandi Common Effluent Treatment Plant (CETP), Tirupur Challenge: Treating effluents for ensuring zero discharge to meet pollution control norms Solution offered: Praj’s ZLD system, which is energy-efficient with proprietary evaporation technology Benefits: The technology helped the dyeing units to adhere to zero discharge norms. In addition, the salts recovered from the CETP plant are re-used by the dyeing units, resulting into considerable savings in operating cost, annually |
The challenge
Following the orders of the Madras High Court, more than 600 bleaching and dyeing units in Tirupur remained closed for almost two years for want of a reliable solution. The court observed that the dyeing units were polluting the river and could not function until zero discharge was achieved.
Textile industry generates high-volumes of wastewater containing various chemical used in dyeing, printing and finishing processes. Since, effluents of dyeing units are highly polluted and dangerous, they have to be treated with right technologies to nullify its harmful effect on the environment. Since characteristics of effluents varies with the type of raw materials used in the dyeing process, adopting right wastewater treatment technology is a challenge.
Though various technologies were implemented at Tirupur, none could solve the groundwater pollution problem effectively. This extended the closure of textile dyeing clusters till the installation of the Zero Liquid Discharge (ZLD) unit by Pune-based Praj Industries which has helped to build confidence for reopening of the textile units in compliance with the pollution norms.
Solution offered by Praj
Praj is one of the leading global players offering innovative solutions to significantly add value in water and wastewater treatment plants, bio-ethanol, bio-diesel, and brewery. Building on its expertise, Praj’s ZLD system, which is energy efficient with proprietary evaporation technology, caters to the various industrial process effluents such as RO reject, complex effluents, cooling tower blow down, etc. The entire basket of technology is available with Praj which forms an integrated part of ZLD system including pre-treatment, biological treatment, tertiary treatment, reverse osmosis, evaporation, crystallisation etc. Praj’s constant focus is always on recycle and reuse of water with its value added technologies.
Praj successfully commissioned a 100-kilo litre per day (KLD) ZLD plant at Veerapandi Common Effluent Treatment Plant (CETP), Tirupur. Praj supplied ZLD technology based on multi-effect evaporation system for textile CETP. The entire plant was designed, engineered, fabricated, erected and commissioned by Praj on turnkey basis.
The final end products are process condensate and salts which are of reusable quality. The reject of existing RO system is first preheated and then fed to the evaporation system in forward feed manner. Praj provided special proprietary designed forced circulation evaporator system. This unique technology is instrumental in solving the groundwater pollution problems arising due to discharge of colorants.
Praj ECOVAP system is suitable for operating at higher solid concentration & viscosity. Suspended solid slurry and precipitating salts can be handled by this system with no chocking issues and with less cleaning cycles.
In order to arrive the most appropriate solution, Praj deployed the best resources and efforts. This involved periodic collection and testing of effluent samples, study of existing effluent treatment plants, developing customised processes & engineering solutions and demonstrating the efficacy of the solution of the first plant at Veerapandi.
Block diagram of the ZLD scheme for Veerapandi CETP (textile effluent)
Growing together
Based on the successful operation of the first plant at Veerapandi CETP, Praj contracted a second order for treating 700-KLD of effluent from the textile dyeing cluster in 2012-13.
Praj later bagged the order from Sirupooluvapatti CETP for treatment of 5000 KLD of effluent, making it the largest installation. It consists of 3 stage treatment including the ZLD system based on multi effect evaporation. “Our ZLD system is energy efficient with low maintenance cost and operates for a longer period between cleaning cycles. The salts recovered from the CETP plant are being re-used by the dyeing units, resulting into considerable savings in operating cost, annually,” opined Pramod Chaudhari, Executive Chairman, Praj Industries.
Advantages of Praj technology:
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