EPA 600/2-76 060
March 1976
Environmental Protection Technology Series
HYPERFILTRATION FOR RENOVATION OF
TEXTILE FINISHING PLANT WASTEWATER
Industrial Environmental Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Research Triangle Park, North Carolina 27711
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RESEARCH REPORTING SERIES '
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into five series. These five broad
categories were established to facilitate further development and application of
environmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields
The five series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
This report has been assigned to the ENVIRONMENTAL PROTECTION
TECHNOLOGY series. This series describes research performed to develop and
demonstrate instrumentation, equipment, and methodology to repairer prevent
environmental degradation from point and non-point sources of pollution. This
work provides the new or improved technology required for the control and
treatment of pollution sources to meet environmental quality standards.
E PA REVIEW NOTICE
This report has been reviewed by the U.S. Environmental
Protection Agency, and approved for publication. Approval
does not signify that the contents necessarily reflect the
views and policy of the Agency, nor does mention of trade
names or commercial products constitute endorsement or
recommendation for use.
This Document is available to the public through the National Technical Informa-
tion Service. Springfield, Virginia 22161.
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EPA-600/2-76-060
March 1976
HYPERFILTRATION FOR RENOVATION OF
TEXTILE FINISHING PLANT WASTEWATER
by
Craig A. Brandon and John J. Porter
LaFrance Industries
Riegel Textile Corporation
LaFrance, South Carolina 29656
Grant No. S800929
ROAP No. 21AZT-006
Program Element No. 1BB036
EPA Project Officer: Thomas N. Sargent
Industrial Environmental Research Laboratory
Office of Energy, Minerals, and Industry
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
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CONTENTS
Sections
I Conclusions
II Reconraendations
III Suitmary
In-Plant Water Reuse
6
Equipment Performance 5
Summary of P~
IV Introduction
Sumtiary of Plant Costs Projections 9
11
14
Objective and Scope
Program Plan
V La France Plant Facility
Fibers and Chemicals Used 14
Wastewater Characterization 16
VI Reuse in Production Dyeings 27
j -- --y *- ^-" ~ - ->j v»
Reuse of Concentrate Water 29
Standard Dyeing Procedure 29
Reuse of Concentrate Water
Reuse of Product Water 33
36
VII Equipment Performance
Pilot Plant 3_
Tubular Cellulose Acetate (Westinghouse) 39
Hollow Polyamide Fiber (DuPont) 44
Spiral-Wound Cellulose Acetate (Gulf) 51
Dynamic Zr(IV)-Polyacrylic Acid (Selas) 54
Design Values for Cost Projections 58
VIII Treatment Plant Cost Projections 61
The Treatment System
Equipnent Description and Capital Cost Projections 63
Operating Cost Projections 75
Cost Projections for a Combined Menbrane System 79
IX References
82
111
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CONTENTS (continued)
Sections
X Appendix A - Water Sampling Schedule, Procedure,
and Chemical Analyses 83
Sampling Schedule 84
Collection and Storage of Samples 84
Analytical Procedures 85
XT Appendix B - Production Scale Reuse Dyeings 89
Cycle #1 91
Cycle #2 95
Cycle #3 98
Cycle #4 , 100
Cycle #5 102
Cycle #6 104
Cycle #7 107
Cycle #8 109
Cycle #9 111
Cycle #10 ' 113
Cycle #12 115
Cycle #14 117
Cycle #16 119
XII Appendix C - Performance of Hyperfiltration Modules
in the La France Pilot Plant 121
IV
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FIGURES
No.
1 BCD of the conposite wastewater 17
2 COD of the conposite wastewater 18
3 Dissolved solids content of the composite wastewater 19
4 Calcium concentrations of the conposite wastewater ' 20
5 pH of the conposite wastewater 21
6 Color content of the conposite wastewater 22
7 Turbidity of the conposite wastewater 23
8 Schematic of pilot plant layout 38
9 Operating performance of Westinghouse nodule at La France 41
10 Cperating evaluation of Westinghouse module during final
500 hours 46
11 Cperating performance of DuPont hollow polyamide fiber
module at La France 49
12 Cperating performance of Gulf (U.O.P.) spiral cellulose
acetate module at La France 53
13 Cperating performance of Selas dynamic membrane module
at La France 57
14 Simplified flow schematic of a textile dyewaste treat-
ment system 52
15 Case 1 - Details of a membrane bank design 66
v
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TABLES
No. Page
1 Sunmary of performance of hyperfiltration modules in
La France demonstration pilot plant 7
2 Summary of cost estimates for treatment of 7570 ra3/d
of textile wastes at La France 10
3 Comparison of hyperfiltration module configurations 13
4 La France size characteristics 15
5 Character!sties of raw composite wastewater during the
operation of the pilot project (March 1973 to May 1974) 24
6 Characteristics of process (tap water) water currently
used in the La France plant 26
7 Production dyeings 28
8 Standard dyeing cycle 29
9 Reuse dyeings of cotton velour with concentrate water 30
10 Analyses of concentrated residues employed in reuse dyeing 32
11 Critical test dyeing formulation 33
12 Analyses of product water 35
13 Operating performance of tubular cellulose acetate West-
inghouse module with La France composite wastewater 43
14 Operating performance of tubular cellulose acetate Vfest-
inghouse module with La France composite wastewater
under variable conditions 45
15 Operating performance of hollow polyamide fiber DuPont
module with La France dyehouse wastewater 48
16 Operating performance of spiral cellulose acetate Gulf
module with La France wastewater 52
17 Operating performance of ceramic tube Zr(IV)-PAA Selas
module with La France wastewater 56
18 Design values for cost projections 59
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TABLES (continued)
No. Page
19 Membrane module capital cost basis for projections 64
20 Details of capital cost projections for hyperfiltration
module unit 68
21 Details of capital cost projections for pretreatment
unit 71
22 Capital cost projection sumnary for hyperfiltration
treatment of La France wastewater 74
23 Operating cost projections sumnary for hyperfiltration
treatment of La France wastewater 76
24 Net operating cost projections summary including
potential recycle credits 78
vn
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A^KNOWLEEGEMENTS
project of this scope obviously is indebted for its success
to contributions of more than one or two individuals. Therefore, Dr.
C. A. Brandon and Dr. J. j. Porter, consultants to the Riegel Textile
Corporation as project director, and principle expert on reuse evalua-
tions, respectively, acknowledge the following people.
The Texidyne pilot plant operators under the guidance of Dr. Ali
El-Nashar, namely, Mr. Bob Adler, Mr. Charles Shuler, and Mr. Eric
Snider have contributed significantly to the large degree of on-stream
time for the pilot plant. The La France personnel including the plant
engineers, Henry McAdory and Ton Foy, and foreman, John Byrura, have been
largely responsible for the expeditious assembling of the pilot plant
equipment and the maintenance thereof. Mr. Charles Smith and Mr. Bernard
Thompson have cooperated to achieve and evaluate the full scale reuse
test dyeings.
Several people less directly involved in the day-to-day operations
have, however, made significant contributions, and are due acknowledgement
and thanks for the consultations: Dr. R. L. Goldsmith and Mr. Sorab
Hassain of ABCOR contributed to this report and to the progress and
success of the pilot plant operations with their continued surveillance
and advice. We also acknowledge the contributions of Dr. J. s. Johnson
' and Dr. R. E. Minturn of the Oak Ridge National Laboratory, along with
the efforts of Mr. George V. Jordan and Mr. George L. Bartholomew, of
Selas Corporation, for their on-going efforts in planning, testing, and
preparation for the second phase of the pilot plant project. The guidance
and direction of Mr. T. N. Sargent, EPA Project Officer, was most valuable
during the course of this study.
Vlll
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SECTION I
CONCLUSIONS
Hyperfiltration (reverse osmosis) has been studied, on a pilot
plant scale, for renovation of the composite wastewater from the textile
dyeing and finishing plant of La France Industries. Both the purified
product water and the residual concentrate were used in full scale pro-
duction dyeings in a two-piece dye beck. The results of this study were
presented in three categories; direct reuse, equipment performance, and
cost projections. The conclusions based on the reuse evaluation results
are:
(1) The quality of the product water, purified by passing through a
hyperfiltration membrane, was satisfactory for direct reuse in all dyeing
and finishing operations at La France.
(2) The technical feasibility of the reuse of the concentrate water,
retained by the hyperfiltration membrane, was demonstrated by the production
of first quality fabric in nine standard shades.
The conclusion drawn from the equipment performance results is:
(3) The four commercial membrane module configurations evaluated in
the pilot plant were each capable of processing textile wastewater, when
operated with proper pretreatment.
The conclusion that attains from the results of cost projections iss
(4) The cost projections for a full scale 2,000,000 gallons/day
(7570 m3/day) treatment facility combining two of the commercial membranes
indicated a capital cost of $1,650,000, and a net operating saving of
43C/1000 gallons (11.3
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SECTION II
HECOM4ENDMTICNS
The result of this investigation demonstrated the feasibility of
hyperfiltration (reverse osmosis) membranes for the renovation of
composite textile dyeing and finishing wastewater at La France Industries.
The scope of the study was limited to the evaluation of performance of
commercial membranes under manufacturer specifications. It was beyond
the scope of this pilot plant investigation to determine optimum pretreat-
ment for textile wastewater. Further, this study was limited to the con-
sideration of plant composite wastewater and the total mixed dyehouse
effluent. The following are recommendations directed toward the optimum
utilization of membrane separations for the economic renovation of textile
wastewater effluents, including direct recycle of single process effluents,
waste treatment of any required system blow down, and modifications of the
manufacturing process that may become economical because of recycling.
(1) The textile wet finishing industry employs a variety of process-
es that each have peculiar waste characteristics. A mobile hyperfiltration
laboratory project is recommended to (a) determine the engineering per-
formance of available hyperfiltration equipment, and (b) to evaluate
potential for reuse at several plants selected to represent the major
categories of dyeing and finishing. A part of this program should be the
study of the treatability of the concentrate since complete reuse may not
prove to be universally practical in the immediate future.
' The favorable economics implied for a combined membrane system suggest
the second and third recontnendations.
(2) Basically hyperfiltration is a separation process. The objective
of the application of hyperfiltration is direct recycle, both of the chemi-
cals in the concentrate and of the product water. It may be more efficient
in many manufacturing processes to make the application of membranes to
individual effluents, rather than to a mixed composite. This is particular-
ly true for the conservation of energy through direct recycle of hot water.
It is recommended that a study be made of the application of membranes
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to the individual effluents of manufacturing processes. In particular,
this study should examine in detail both batch and continuous operations
in order to assess the potential inpact of energy conservation, through
recycle of hot process water and the reuse of reconcentrated chemical
baths, upon the textile industry.
Since the potential for economic recovery, for certain processes
where significant energy and chemical savings are possible, the accept-
ability of membrane separation technology for point source application
is enhanced. The recovery of any process chemical by direct recycle will
also obviously reduce the pollutional load in the remaining composite
wastewater.
Because the economics are potentially conducive to early adoption
by industry, and because the removal of expensive chemicals and energy
by direct recycle achieve a significant reduction in the pollutional load
(often of the more refractive constituents, e.g., PVA and vat dyes), it
is further recommended that as a second phase of the study of point source
recycle be a full scale demonstration. The full scale demonstration
should involve closed cycle operation of a manufacturing process. Closed
cycle will provide a necessary demonstration of the effects of recycle on
the manufacturing process. In addition, it will permit the full scale
evaluation of process modification.
(3) As the full scale demonstration of membrane separation for
point source recycle is a second phase of an assessment study, the full
scale demonstration of the renovation of composite wastewater is recommend-
ed as a second phase of this pilot plant project and the mobile hyper-
filtration laboratory project recommended above. Closed cycle operation
would provide information on (a) the equipment performance over an ex-
tended period, (b) the change in process water composition, and (c) the
treatment of any blow down required. A full scale membrane system would
also provide a useful test bed for the study of pretreatment to minimize
the total cost of the treatment system.
The demonstration of the renovation of composite wastewater would be
beneficial because there are a number of instances in which this could be
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a useful intermin step to full scale totally closed cycle. For example,
in a few cases, water availability and costs (supply and treatment) are
such that recycle is a viable alternative to minicipal systems. Further
full scale demonstration of the renovation of composite wastewater would
not be redundant in that application of point source recycle would only
tend to optimize the performance of the integrated system and to maximize
the rate of return from recycle.
Since the cost of the membrane modules is the significant factor in
determination of the economic practicality of this separation technology,
the following recommendations relate to improvenent in the equipment
performance with textile wastes.
(4) Development of washing procedures to prevent flux decline, i.e.,
fouling, or to restore flux periodically. Costs potentially may be
reduced up to 50%.
(5) Development of pretreatment to reduce membrane fouling in
order to both increase average flux and prolong membrane useful lifetime.
(6) Development of membranes tailored to the separation of the
specific chemicals, e.g., for use with process solvents other than water.
(7) Development of membrane modules designs and determination of
fluid dynamics to minimize horsepower requirements.
(8) Evaluation of the potential for the chemical recovery from
concentrate as a raw material for a chemical process.
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SECTION III
SUMMARY
This report describes the results of the hyperfiltration (reverse
osmosis) demonstration pilot plant at La France Industries which was in
operation during 1973-74. Both the purified product water and the con-
centrate water representing 65 - 95% water recovery have been recycled
successfully in full scale test dyeings during the period of operation
of this program.
IN-PLANT WATER REUSE
This pilot study was conducted to demonstrate the feasibility of re-
use of treated textile wastewater in plant (full) scale dyeing operations.
This method of treatment was hyperfiltration which yields a relatively
pure fraction of water, referred to as product water, and an impure
fraction containing most of the dyes and chemicals, referred to as con-
centrate water.
Sixteen different treatment cycles were performed during the course
of the project. Thirteen of these cycles used the treated water in plant
scale dyeing operations. Three cycles were devoted entirely to equipment
performance determinations. The product water was used in five dyeing
operations with standard dye formulations. The product water was used
with the concentrate in five dyeing operations. Eight plant scale dyeings
were made in which the concentrate was used as. the initial dye bath with
normal plant water used for all other process steps. A total of eighteen
plant scale dyeings were performed. A total of eleven different dye
formulations evaluated the success of using the product water and con-
centrate water for plant scale dyeings.
All of the plant dyeings were successful. No significant problems were
encountered with the reuse of product or concentrate water. The light fast-
ness wash tests performed on the fabric, as a quality control measure,
established that the test dyeings were equal to normal production quality.
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Test dyeings were conducted in the laboratory before plant scale dye
formulations were chosen. The product water required no additional
treatment and could be used interchangeably with plant water. Concen-
trate water sanples frcm each cycle contained concentrations of different
dyes. The dye formulation chosen for use with the concentrate water re-
quired minor additions of dye when the concentrate water contained
cotpatible colors and major additions of dye when the recovered dye was
different. This results in dye savings in seme cases and an increase in
dye requirements in other cases. The average reduction of dyes was 16%.
i
EQUIPMENT PERFORMANCE
Three types of hyperfiltration membranes were evaluated during the
course of this demonstration pilot plant; polyamide, cellulose acetate,
and Zr(IV)-polyacrylic acid. Cellulose acetate was evaluated in two
membrane configurations. A total of four basic commercial module con-
figurations were therefore investigated. These were:
(1) Tubular cellulose acetate on the internal wall of 13 nm diameter
tubular channels,
(2) hollow-fine polyamide fibers,
(3) spiral-wound sheets of cellulose acetate, and
(4) external coating of Zr(IV)-PAA dynamically deposited on ceramic
tube bundles.
The operation of these units is summarized in Table 1.
A single Westinghouse tubular cellulose acetate module was operated
for over 1000 hours. Pretreatment employing 25 micron cartridge filters
was enployed. The pH was maintained in the range 5.2 - 7.0, and the
temperature controlled below 90 F (32 C), as recoranended by the manu-
facturer. The average rejections of COD, total solids, conductivity, and
color range from 92 - 99+%. There was a decrease in product water flow
rate from the unit with time of operation that was partially recoverable
by washing.
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Table 1. SUGARY OF PERFORMANCE OF HYPERFILTROTION MDDULES IN IA FRANCE DEMONSTRATION PILOT
MANUFACTURER
MEMBRANE
CONFIGURATION
TEST DATE
HOURS OF TEST
TEST CONDITIONS
Prefiltration
pH
Temperature, C
Pressure, Pa (x 10~6)
AVERAGE REJECTIONS, %
Total Solids
Color
Conductivity
COD
Westinghouse
Cellulose
Acetate
internal
tubular
12/73 - 1/74
1059
25 micron
cartridges
5.6 - 7.0
13 - 32
2.1 - 3.1
95
99+
92
96
DuPont
Polyaitu.de
hollow-fine
fiber
2/74 - 3/74
187
D.E.C
6.2 - 8.3
11 - 32
2.4
95
99+
94
92
Gulf13
Cellulose
Acetate
spiral-wound
4/74
804
25 micron
cartridges
5.8 - 7.0
15 - 26
2.8
96
99+
95
94
Selas Flotronics
Zr(IV)-PAA
externally coated
tube bundle
6/74 - 7/74
944
250 micron screen
6.6 - 8.5
20 - 91
2.4 - 7.2
90
98+
85
95
b Total plant composite and dyehouse wastewaters used in this
c Now ROGA, a Division of Universal Oil Products
Diatonaceous earth - Sears swiitming pool filter - preceeded
study.
25 micron and 1 micron cartridge filters.
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Three DuPont permeators employing the hollows-fine polyamide fibers
were operated, below 90 F (32 C), for a total of about 600 hours. After
greater than 400 hours of operation on composite wastewater from the
total plant, it was recommended by DuPont that further evaluations be
made with wastewater from the dyehouse only, excluding all sanitary and
finishing wastewaters. During the last 200 hours, a diatomaoeous earth
prefilter was used in addition to the 25 micron and 1 micron cartridge
prefliters which were used for the initial 400 hours. The penreator
evaluated during the last 200 hours, under these recommended conditions,
performed satisfactorily. The average rejection of COD, total solids,
conductivity, and color ranged from 92 - 99+%. It was possible to main-
tain the product water flow rate from the module by intermittent deter-
gent washing.
The Gulf (now POGA, Division of Universal Oil Products) spiral-wound
cellulose acetate module was operated for 804 hours. The pH was maintain-
ed in the range 5.8 to 7.0, and the temperature controlled below 90 F
(32 C). All wastewater was prefiltered through 25 micron cartridge filters,
During the initial 163 hours an additional 1 micron cartridge filter was
used in series with the 25 micron filter. The average rejections of ODD,
total solids, conductivity, and color ranged from 94 - 99+%. There was
an initial decrease in product water flow rate of the unit, however,
operation over the last 600 hours was at a stable rate.
Two types of units containing dynamic membranes were used during the
course of this pilot plant project. Initially, dynamic membrane modules,
prepared by consultants at the Oak Ridge National Laboratory, were used
to generate sufficient product and concentrate to demonstrate full scale
reuse. The performance of the ccmnercial modules provided by Selas is
summarized in this report.
The Selas dynamic membrane module contained eight, 19-tube bundles
in series. The Zr(IV)-PAA membranes were deposited on these ceramic tubes
and then operated for 944 hours. (This period included approximately 170
hours of operation with rinse water from an indigo dye range.)
The pH of the raw feed was not adjusted. The unit was operated with
8
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40 mesh prefiltration over a temperature range fron 68 - 195 F (20 -
90 C). The average rejections of conductivity, total solids, GOD, and
color ranged from 85 - 98+%. The product water flow rate from the unit
decreased sharply initially but achieved a stable rate.
SUTWARY OF PLANT COSTS PROJECTIONS
The equipment performance data were used by each module vendor to
prepare a cost projection for a complete 2 million gallon per day
(7570 m3/d) hyperfiltration wastewater plant for the La France facility.
These projections include pretreatmant costs for control of pH, tempera-
ture, and suspended solids, as required for each membrane configuration.
These estimates do not include reservoir storage facilities, or treatment
of the 10 to 20 percent make-up water required in the plant.
There is a wide variation in both the capital cost and the daily
operating costs. Major daily cost items for the polyami.de and cellulose
acetate membrane systems are membrane replacement and electrical power
costs. The major cost item for the dynamic membrane system is electrical
power.
The capital cost and the operating power costs for each hyperfiltration
plant are directly related to the number of module units required. There-
fore, the pilot plant determinations of the product water flow rate from
each module ware critical to meaningful cost estimate determinations. A
summary of cost estimates is given in Table 2.
It is very important to note that these cost-data do not include the
value of recyclable water, chemicals, or heat (energy). Using the esti-
mated values of recycled materials and water as indicated in Table 2, the
cost reduction for each of the polyamide and cellulose acetate membrane
systems is 57$/fegal (15<=/m3). Because of the possibility of direct re-
cycle of 25% of the water at process temperature, the dynamic membrane
system may have a cost reduction of as much as 69C/kgal (32<:/m3). A
system combining two membrane types may have a cost reduction of as much
as 88.5CAgal (23.4
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Table 2. SUMMARY OF COST ESTIMATES FOR TREATMENT OF 7570 m3/d OF TEXTILE WASTES AT LA FRANCE
MEMBRANE CONFIGURATIONS
CAPITAL INVESTMENT, $
DAILY OPERATING COSTS, $/d
1. Pretreatment Chemicals
a. Filter Aid
b. Chemicals
2. Labor
a. Operating
b. Maintenance
c. Supervision
3. Maintenance Materials
4. Electric Power
5. Membrane Replacement
Total
DAILY OPERATING COSTS, C/ta3
RECYCLE POTENTIAL, C/fri3
1. Salt (80% recovery
@ 4.4<:/kg)
2. Water (80% recovery
@ 13
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SECTION IV
INTRODUCTION
Increasingly stringent requirements for treatment of wastewfcter,
and significant surcharges which have been introduced by municipalities
require that we evaluate wastewater treatment systems which provide re-
cycle capabilities. Hyperfiltration1/2 (reverse osmosis) is a technique
for economical renovation of industrial wastewaters which may yield
recovered chemicals, relatively pure product water, and energy where hot
water can be directly recycled in a process.
Hyperfiltration is a membrane separation process that selectively
filters soluble and insoluble chemicals frcm water. This technology has
been used successfully in selected industrial applications where the re-
covered products have significant value. This study investigated the
application of hyperfiltration for the recovery of water and chemicals
from the wastewater of a textile plant. The purified product water and
the concentrate water were directly recycled in full scale production
dyeings.
The results from this study are in agreement with previous laboratory
tests of hollow-fine fiber permeators and dynamic membrane hyperfiltration
test sections.3 This deraonstration pilot plant was operated by La France
Industries, ^ Division of Riegel Textile Corporation, in cooperation with
participating equipment conpanies under an Environmental Protection Agency
grant.1* The characteristics of the La France facility and wastewater
stream are summarized in this report.
OBJECTIVE AND SCOPE
The primary objective of this pilot plant project was to demonstrate
the direct reuse of renovated textile wastewater in full scale production
dyeing equipment using standard procedures. Additional goals were to de-
monstrate the practicality of hyperfiltration equipment and develop cost
estimates for a full scale plant.
11
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When a major portion of the wastewater is renovated and recycled a
blow down stream will ultimately be required to prevent chemicals from
accumulating to intolerable levels in a closed system. The composition
and disposition of such a blow down were beyond the scope of this project.
There are several configurations of conrnercial hyperfiltration
equipment. The characteristics of the types of systems available are
presented in Table 3. The scope of this project was to demonstrate the
performance of each of these conrnercial and prototype modules.2'5~7
PROGRAM PLAN
The program plan included 16 monthly test cycles. In thirteen cycles
product water was used in plant scale dyeings. Operation over 16 months
permitted a complete study of the seasonal production variations in the
mill.
Before this project was started, tests were conducted on laboratory
scale with hyperfiltration equipment to establish the feasibility of treat-
ing the waste stream at La France. Technical feasibility was indicated
by these tests and the pilot plant was installed and full scale reuse
tests were begun.
The size of the pilot plant equipment was selected to permit the full
scale operation in the dyeliouse of a production dyeing beck, with a capa-
city of 92 meters of fabric. The hyperfiltration unit was sized»to accumu-
late, in each test cycle, approximately 17 m3 of product water and 5.7m3
of concentrate. These volumes were sufficient to permit a full scale
dyeing by standard procedures. The first week of each cycle was devoted
to the collection of this purified water by the processing of approximately
22.7 m3 of raw wastewater taken directly from the corposite sewer main
leaving the plant. During the latter stages of the project raw wastewater
could be taken from either the composite sewer or the dyehouse drain.
The original period of investigation for this grant was for 20 months.
The study began July 12, 1972, the initial operation of the pilot plant
began on March 12, 1973, and was completed July 31, 1974.
12
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Table 3. COMPARISON OF HYPERFILTRATION MODULE CONFIGURATIONS
Membrane Material
Production Rate
m3 /fa3 /day
Method of Membrane
Replacement
High Pressure
Limitation
Particulates
in Feed
Permissible Feed
Range, pH
MaxLmun
Temperature, F (C)
Spiral
cellulose
acetate
67 - 1000
module
(on-site)
membrane
compaction
filtration
required
5.5 - 7.5
100 (38)
Tubular
cellulose
acetate
13 - 200
tubes
(on-site)
membrane
compaction
no problem
5.5 - 7.5
100 (38)
Hollow-Fine Fiber
polyamide
27 - 2000
module
(on-site)
fiber collapse
filtration
required
2-10
100 (38)
Dynamic
hydrous Zr(lV)
oxLde-polyacrylate
200 - 2000
in-situ
no problem
no problem
4-11
>195 (>90)
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SECTION V
LA FRANCE PLANT FACILITY
The parameters describing the production capacity of the La France
plant are shown in Table 4. These data provide a basis for cortparison
and evaluation of the results of this demonstration project. These
factors are inportant in the ultiinate estimation of the practicality of
scale-up from the pilot plant.
The process water is from La France's own filter plant. Ninety-
five percent of the 7570 m3 per day total water usage is in the dyehouse.
Allowing for considerable evaporation by drying, the composite waste
stream is at least 85% by volume dyehouse wastewater. This is verified
by the average total dissolved solids (TDS) measured in the composite
waste. The 7600 Ibs/day (3455 kg/d) of salt used are equivalent to
500 mg/Jl of dissolved solids in the composite wastewater.
The materials involved in potential recycle with hyperfiltration are
the water, the salt, and the unexhausted dyes. In the case of membranes
that can withstand high temperatures, energy can also be recovered by
direct recycle of renovated hot water. The economic potential for re-
covery of salt, water, and energy is greater than $1500/day. A signifi-
cant cost item is the $800/day cost for water treatment which may be
reduced by recycling water. An additional economic incentive is the
recovery of dyes. These potential savings will reduce the net cost of
this type of waste treatment and may pay for part or all of the operating
cost.
FIBERS AND CHEMICALS USED
The dyeing and finishing processes at La France involve several dif-
ferent dyes and finishes. The dyeing is done in open-beck, piece dyeing
machines. The principal classes of dyes employed are neutral pre-metal-
lized, direct, and acid dyes. These account for about 95% of the total
dye usage. Other dyes used in smaller quantity are disperse, basic, and
14
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Table 4. IA FRANCE PRODUCTION CAPACITY PARAMETERS
QUANTITIES USED
Materials :
Water (total to plant) , m3/day 7,197
(gallons/day) (1,900,000)
Water (to dyehouse) , m3/day 6,818
(gallons/day) (1,800,000)
Dyes, kg/day 225
(pounds/day) (500)
Cloth, m/day 20,000
(yards/day) (22,000)
Salt, kg/day 3,454
(pounds/day) (7,600)
Energy:
Fuel Oil (for process steam), joules/day 1.05 x 10 12
(Btu/day) (1.0 x 10 9)
UNIT COSTS
Water, C/m3 13
($/1000 gallons) (0.50)
Fuel Oil, «/107 joules 1.9
($/106 Btu) (2.06)
Salt,
-------
reactive dyes. The finishes used include silicone, latex, wax dis-
persions, fluoro-chemicals, and flame retardants. These finishes
represent, at most, a few parts per million in the composite waste
stream.
The materials processed are nylon (30%), viscose (20%), and cotton
(50%), with approximate weight percentages indicated.
WASTEWATER CHARACTERIZATION
The variety of dyes and finishes employed produce a complex and
variable waste stream composition. The quantitative characterization
of the waste stream is important in evaluation of the pilot plant.
Daily samples of the composite waste stream were collected at random
times and ccmposited weekly for analyses. The results of typical analy-
ses are tabulated in Table 5. The variation of several of the significant
parameters is indicated in Figures 1 through 7. The sampling and
analytical procedures are shown in Appendix A.
As shown in Figure 1, the BOD varied within the range 20 - 125 mg/2,
with an average near 40 mg/Jl. In Figure 2, approximately the same per-
centage variation is indicated for GOD, from 125 - 900 mg/5,. No simple
correlation between BOD and COD is apparent frcm these data. In Figure 3,
the total dissolved solids average 1000 mg/£, with a range from 600 - 1200
mg/ji. The calcium content, Figure 4, varies from 0.5 - 7.2 mg/£. The
pH, an important parameter for selection of hyperfiltration equipment (see
Table 3) stays in the neutral range, Figure 5, during most of this period;
the maximum values about 8. In some cases the pH was measured about 10;
however, this level of pH was noted only rarely and could be adjusted by
equalization or chemical neutralization.
The color of the waste stream shown in Figure 6 also varies widely.
This was expected and is typical of dyehouse wastewater. The turbidity
shown in Figure 7 is attributable mostly to small fibers from velvet
fabrics sheared in the plant.
Values of selected parameters were determined by the pilot plant
operators for each of the 600-gallon batches of raw feed collected for
16
-------
140.
120.
MARCH APRIL MAY JUNE
1973
JULY AUGUST SEPT. OCT. NOV. DEC. JAN. FEB. MARCH APRIL MAY
1974
Figure 1. BCD of the composite wastewater.
-------
1000.
80O,
00
-6OO.
O
O
U
400
20O
T:
MARCH APRIL MAY JUNE JULY AUGUST SEPT OCT. NOV. DEC. JAN. FEB. MARCH APRIL MAY
1973 1974
Figure 2. COD of the cotposite wastewater.
-------
I20O.
MARCH APRIL MAY JUNE JULY AUGUST SEPT OCT. NOV. DEC. JAN. FEB. MARCH APRIL MAY
1973 ,974
Figure 3. Dissolved solids content of the conposite wastewater.
-------
MARCH APRIL MAY JUNE JULY AUGUST SEPT OCT. NOV. DEC. JAN. FEB. MARCH APRIL MAY
1973 1974
Figure 4. Calcium concentrations of the composite wastewater.
-------
(
MARCH
1973
^
APRIL
0 QL
/\ 7^
*^
An
f 0o
^^
V
f
iy
I©«Q^-
^XSL
"- ,
f*\
MAY JUNE JULY AUGUST SEPT. OCT. NOV. DEC. JAN. FEB. MARCH APNIL MAY
1974
Figure 5. pH of the composite wastewater.
-------
1500,
1300.
to
to
5
u
a
IIOQ
9OO.
700.
5OO
300.
MARCH APRIL MAY JUNE JULY AUGUST SEPT. OCT. NOV. DEC. JAN. PER MARCH APRIL MAY
1973 1974
Figure 6. Color content of the composite wastewater.
-------
ISO.
NO
LJ
MARCH APRIL MAT JUNE JULY AUGUST SEPT. OCT. NOV. DEC. JAN. FEB. MARCH APRIL MAY
Figure 7. Turbidity of the composite wastewater.
-------
Table 5. CHARACTERISTICS OF RAW COMPOSITE WASTEWATER DURING THE
OPERATION OF THE PILOT PROJECT (March 1973 to May 1974)
COD, mgA
BOD, mgA
TOC, mgA
pH
Alkalinity/ mgA
Hardness, mgA
Total Solids, mgA
Volatile Solids, mgA
Dissolved Solids, mgA
Suspended Solids, mgA
Color (Pt-Co units)
Turbidity, F.T.U.
Conductivity (ymho/cm)
Metals
Calcium, mgA
Zinc, mgA
Magnesium, mgA
Chromium, mgA
Copper, mgA
Iron, mgA
Mercury, pg/&
Manganese, mgA
Sodium, mgA
Minimum
160
20
30
6.0
40
20
640
95
640
0
280
1.7
800
0.9
2.0
0.51
<0.1
0.04
0.2
0.46
<0.1
190
Maximum
880
125
168
7.6
90
80
1280
460
1195
135
1660
120
2160
2.9
6.0 ,
4.0
0.3
0.20
4.2
1.08
<0.1
440
Average
303
46
73
6.75
54
36
935
180
881
55
757
39.4
1290
1.4
3.8
2.9
<0.13
0.11
1.2
0.76
<0.1
290
24
-------
processing by the hyperfiltration equipment. The miniiuum, maximum, and
average values of these parameters are presented in Table 5.
Because of the batch-type operation of the dye becks, there are
periods when the waste stream is predominately wash water and other
times when spent dye solutions cause the waste to be relatively highly
concentrated. The sample selection for pilot plant use was randan and
somewhat biased toward higher levels of contaminants and color by the
investigators' desire to avoid dilute wastewater. The treatment results
are felt to be slightly conservative as wastewater characterization.
A final variable not measured directly, but of importance to all
hyperfiltration except dynamic membranes, is fluid temperature. It
was necessary to install a heat exchanger to maintain process temperature
in the hyperfiltration unit in the safe operating range, less than 90 F
(32 c) for the cellulose acetate and polyamide membranes (see Table 3).
Samples of process water were taken in the dyehouse at the tine of
the full scale reuse test dyeings. The chemical analyses were selected
to permit a direct comparison with the recycled water. The results pf
the analyses of nine samples are summarized in Table 6.
25
-------
Table 6. CHARACTERISTICS OF PROCESS (TAP WATER) WATER CURRENTLY
USED IN THE LA FRANCE PLANT
COD, mg/Jl
BOD, mg/Jl
TOC, mg/Jl
pH
Alkalinity, mg/Jl
Hardness, mg/Jl
Total Solids, mg/Jl
Volatile Solids, mg/Jl
Dissolved Solids, mg/Jl
Color (Pt-Co units)
Turbidity, F.T.U.
Conductivity (ymho/on)
Metals.
Calcium, mg/Jl
Zinc, mg/Jl
Magnesium, mg/&
Chromium, mg/Jl
Copper, rag/A
Iron, mg/A
Manganese, mg/Jl
Sodium, mg/Jl
Minimum
<1
0.2
1
5.8
12
9
45
10
45
2
0.15
60
1.0
0.07
0.40
<0.1
<0.04
<0.15
<0.05
5
Maximum
20
2
5
7.4
35
30
85
55
65
35
4.1
100
2.0
0.56
1.28
<0.1
0.04
1.2
0.11
10
Average3
9
0.8
4
6.7
22
16
61
26
56
11
1.1
75
1.32
0.24
1.02
<0.1
<0.04
0.90
_b
8
a This is the average of 9 separate samples taken March 1973 to May 1974.
b There are too few data for manganese for a meaningful average.
26
-------
SECTION VI
REUSE IN PBDDUCTIOM DYEINGS
The reuse dyeings were calried oufc in a ^.^ ^ fcl
standard plant procedures. Normally the dyeings were dons at the
beginning of the third v«* of each of the ^nthly test cycles. After
the collection of 17 m3 of purified product water and 1.5 n,3 to 3.8 m3
of residual concentrate was coated, ndxed samples of each v^re taken
for analyses, rnese dyeings ware conducted in the laboratory so that
production scale formulations oould be developed. The production
ayemg formula was then given to the plant dyer who coveted the
standard dyeing procedure.
Two types of pl^t dyeings ^ ^^^ ^ ^ ^ ^^
(1 separate and independent dyeings employing only product water or
only concentrate, and (2) one dyeing coining both the concentrate
-d Product water, a. ^n^^^ was ^ ^ ^ ^^
^tronal dyes added as prescribed in the formation prepared in the
laboratory. The product water was substituted for tap water in each
step in the standard dyeing procedure.
Eighteen separate production dyeings ware conducted with recycled
product water arf/or concentrate in the period Ifcrch 1973 to July 1974
These are listed in Tab!e 7 by cycle nu*er whi* refers to operating '
psraods, see append* B. me water recovery, i.e., the portion of the
wastewater recovered as purified product water, is indicated for each
test. Also, the performance of the nateanes in terms of measured con-
and color reactions is listed. The higher rejections are
of better c^ali^ product water and hence stronger concentrate.
water recovery generally means lower quality product water ana
stronger concentrate. Details of each production dyeing are given in
Appendix B.
27
-------
Table 7. PRODUCTION DYEINGS
to
CO
Cycle
number3
1
2
3
4
5
6
7
8
9
10
12
14
16
Membrane
Type
Polyamide
Polyamide
Poly5ara.de
Polyamide
Polyamide
Polyamide
Zr(IV)-PAA
Zr(IV)-PAA
Zr(IV)-PAA
Cellulose
Acetate
Polyamide
Cellulose
Acetate
Zr(IV)-PAA
Type of Water Used,
for Plant Dyeings
Product & Concentrate
Product & Concentrate
Combined
Combined
Combined
Product & Concentrate
Concentrate
Concentrate
Product & Concentrate
Product & Concentrate
Combined
Combined
Concentrate
Water
Recovered
(%)
75
75
75
90
90
90
75
75
75
75
75
75
75
Conductivity
Rejection
M
90
90
90
90
82
75
85
65
72
92
95
95
88
Color
Rejections
<%>
98
98
99
99
98
86
99
98
99
99
99
99
99
Cycles 11, 13, and 15 were equipment study cycles in which no water was saved for reuse dyeings.
In some cycles, product and concentrate water were used separately in different dyeings and in
seme cvcles thev were combined for a sinale dveina.
»* - -
seme cycles they were combined for a single dyeing.
-------
STANDARD DYEING PROCEDURE
The standard dyeing cycle involves the six-step procedure listed
in Table 8.
Table 8. STANDARD DYEING CYCLE
Operation.
Scouring
Flush Bath
Dyeing
Adjust Ahade
Flush Bath
Dye Fixing Agent
Chemicals
Detergent
Dyes and Salt
Dyes
Water Used
(m3)
1.9
1.9
1.5
2.3
Temperature
(0
50 - 82
27
50 - 93
93
27
27
REUSE OF CONCENTRATE WATER
Two types of tests were run classified by the procedure for select-
ing the shade to be dyed. Routimly the procedure was to select a shade
in the immediate production schedule and add whatever dyes were needed to
match the shade. Occasionally a shade was selected from the production
catalog to be nearest that produced by the concentrate, therefore requiring
nammal amounts of additional dyes. The first type of dyeing illustrates
the technical feasibility of recycling the residue, even if only occasion-
ally the production schedule may permit significant savings of dyes. The
second type of dyeing indicates the optimum savings of dyes in recycled
concentrate. Both types result in effective recycle of the concentrate
tod thus avoid the cost of waste treatment. Successful production dyeings
were achieved for both light and dark shades.
All the dyeings with concentrate are listed in Table 9. With a
single exception, 100% cotton velour fabric was used in the concentrate
29
-------
Table 9. REUSE DYEINGS OF COTTON VEDOUR WITH CONCENTRATE WATER
CO
o
Cycle
nurrber
1
2
3a,b
4b
5b
6
7
8C
1213
14b
16d
Weight of
Fabric (kg)
21.6
43.83
36.9
38.25
36.9
88.65
68.85
45.0
23.4
70.65
16.2
Shade
Tan
Blue-green
Light Blue
Rose
Violet
Tan
Rose
Blue-green
Burnt-orange
Gold
Green
Nurrber
Reuse
Test
3
2
1
3
2
3
3
2
3
4
3
of Dyes
Standard
Test
4
2
3
3
2
4
3
3
3
3
-
Amount of Dyes
(% of Fabric Weight)
Reuse
Test
0.412
10.48
0.055
0.233
0.130
0.305
0.310
0.485
1.450
0.990
0.235
Standard
Test
0.438
0.932
0.189
0.302
0.130
0.438
0.189
0.632
1.940
1.033
-
Fabric conposition this test: 65% Cotton - 35% Rayon
Product and concentrate water were used together.
Results from Cycle #9 and #10 are incomplete.
This shade is not a standard item.
-------
reuse dyeings. During Cycle #3, a 65% cotton - 35% rayon blend fabric
was dyed. Nine different standard shades were dyed. The tan shade
dyed in Cycle #1 was repeated in Cycle #6. ihis was done to (1) show '
that the shade for the reuse dyeing could be selected independently of
the conposition of the concentrate, and (2) provide a direct comparison
of results achieved for 75% and 90% water recoveries. In each case the
finished product was graded as first quality.
Dye formulations developed for the reuse tests generally were no
nore conplex than the standards, The number of dyes employed are in-
dicated in Table 9 for each reuse test. The amount of dye used in the
reuse tests are listed with the standard for the shade. The corrparison
indicates a wide variation in the dye savings. In two cases, Cycle #2
and #7, more dye was required with the concentrate than in the standard
formulae. The average of the 10 comparisons is, however, a 16 percent
reduction in dye required to achieve standard shades.
A limitation of the reuse of ^concentrated dye residues is that
they often yielded a dull grey color. Thus a darker shade had to be used
so that the dullness would not affect the color of the finished fabric.
in the 11 test cycles, successful production dyeings were achieved for'
both light and dark shades, hoover. The finished fabrics were generally
the equivalent to standards in crocking and 40-hour Fade-OMeter tests.
The analyses of the concentrated used in the reuse dyeings are given
in Table 10.
31
-------
Table 10. ANALYSES OF CONCENTRATED RESIDUES EMPLOYED IN REUSE DYEING
co
to
Constituent (mg/Jl)
COD
BOD
roc
pH
Alkalinity
Hardness
Total Solids
Volatile Solids
Dissolved Solids
Color (Pt-Co units)
Turbidity, F.T.U.
Metals
Calcium
Zinc
Magnesium
ChromLum
1
425
70
87
6.7
110
90
2360
200
2330
850
39
3.0
9.7
1.2
2
815
135
200
6.5
135
120
5570
450
5540
1250
31
-
-
-
<0.1
Cycle Number
3
455
60
110
7.0
110
80
2545
280
2480
1500
2
-
-
-
<0.1
4
580
102
165
7.2
160
90
3020
310
2985
1000
40
6.5
-
10.2
_
5
690
95
220
7.2
190
135
4425
405
4230
1200
30
9.0
8.5
13.8
0,1
6
435
10
-
7.4
140
130
3425
315
3435
1250
80
6.0
9.0
17.0
_
7
190
15
-
8.0
155
50
1580
165
1480
1300
8
1.0
2.4
4.5
_
8
415
45
-
7.5
115
55
2510
275
2450
1680
15
8.1
3.1
9.6
_
12
365
15
-
6.8
95
245
4320
245
4320
920
4
34.0
7.2
27.0
_
14
430
20
230
6.7
160
190
3025
275
3025
1100
35
7.5
3.0
15.0
0.6
16
255
55
100
9.0
250
130
3110
-
3055
190
18
15.5
1.8
12.0
_
-------
REUSE OF PRODUCT WATER
The purified product water was used instead of tap water in each
step of the standard dye procedure. Two types of tests were run classi-
fied by the use of product water in combination with the concentrate or
with a standard dye formulation. The use of the product water in the
production dyeing of a standard light shade, considered by the plant
dyer to be the most difficult dye system in the plant, was expected to
magnify any difficulties in the recycle of product water. This critical
dyeing, done on a 54% nylon - 46% viscose automotive upholstery fabric,
contained the formulation given in Table 11.
Table 11. CRITICAL TEST DYEING FORMULATION
Chemical Dye Name
Acid Dye Nylon Fast Yellow FLW
Acid Dye ciba Brown 2GL
Acid Dye ciba Yellow 2BRL
Acid Dye Irgalan Black RBL
Direct Dye Lumicrease Grey 3LBN
Direct Dye Lumicrease Orange 3LG
Direct Dye Lunicrease Bordeau 3LR
This critical test of the reuse of product water was carried out four
times; Cycle #1, #6, #9, and #10. This test was thus used for each type
of membrane and for each level of water recovery. In each case, this pro-
duct water was used for all steps from scouring to final rinsing. The shade
was obtained with no difficulty following routine procedures. The finish-
ed fabric passed 100-hour Vfeather-O-Jfeter test for color fastness.
In Cycle #2, product water was used to dye a yellow shade on a cotton
ribbed velour fabric. The dyeing followed routine procedures with the
33
-------
product water used in all steps. The appearance of the finished fabric
was normal and crocking and light fastness were standard. After
completing Cycle #2, it was apparent that the product water could be
substituted freely for normal tap water in this plant's production
dyeings.
The analyses of the product water used in all reuse dyeings is
given in Table 12. The average of a number of analyses of tap water,
collected at the time and at the place of the test dyeing is given for
conparison. In general, the product water contains more solids than
the tap water, but has lower concentrations of metals.
34
-------
Table 12. ANALYSES OF PRODUCT WATER
U)
tn
Constituent (mcr/ji)
COD
pnn
TCC
pH
AUcalinity
Hardness
Total Solids
Volatile Solids
Dissolved Solids
Color (Pt-Co units)
Turbidity (F.T.U.)
Metals
Calcium
Zinc
Magnesium
Chromium
Copper
Iron
Mercury (ugA)
Manganese
Sodium
1
25
10
3
6.1
10
30
100
30
100
30
2.4
0.5
<0.04
<0.01
0.04
0.3
*
2
20
5
4
6.0
15
15
270
N.D.
270
20
0.5
0.1
<0.13
N.D.
<0.1
3
20
5
4
6.4
15
20
130
20
130
13
1.3
-
<0.4
0^56
_
4
15
4
4
6.5
15
5
280
40
280
6
0.8
0.24
0.28
-
94
Cycle Number
5
15
0.3
4
7.1
25
5
440
40
440
30
3.4
0.10
0.08
0.22
0.1
160
6
25
1
7.2
15
10
285
60
285
60
6.3
0.5
0.7
0.9
0.8
90
9
30
2.7
6.2
40
4
630
95
630
30
1.5
0.17
0.06
0.58
0.63
270
10
200
1.3
6.2
3
6
215
75
205
60
6
0.88
0.82
0.78
1.13
55
12
10
2
6.4
10
3
230
65
230
20
2.0
1.00
0.50
0.42
-
0.04
75
14
25
1
5
5.9
8
0.5
45
15
50
40
2.5
0.08
0.04
0.02
Oin
-LU
0.04
0.14
0.03
15
Tap
Water
<4
0.6
6.7
27
19
67
36
59
13
1.11
1.45
0.07
0.96
<0.04
<0.68
<0.05
10
-------
SECTION VII
EQUIPMENT PERFORMANCE
A major goal of the project was to demonstrate the practicality of
hyperfiltration equipment in an actual plant-site evaluation. This
goal was accomplished by evaluating four commercial membrane modules in
a pilot plant. The layout and operation of the pilot plant are described
prior to presentation of the performance data for each membrane module.
Specific pretreatment of the wastewater feeds to the membrane
modules, e.g., fine filtration, pH adjustment, and temperature control,
was utilized as required by manufacturer specifications. However, limited
attention was given to the study of pretreatment, and certainly no opti-
mization of pretreatnent for textile wastes was attempted. Because of the
strong influence of membrane flux on hyperfiltration treatment plant
costs, the evaluation of means to minimize flux decline is important.
Three membranes were evaluated; polyamide, cellulose acetate, and
Zr(IV)-polyacrylate. Cellulose acetate was evaluated in two configurations,
thus four commercial module configurations were evaluated: (1) tubular,
cellulose acetate membranes on the internal wall of 13 ran diameter channels6,
(2) hollow-fine polyamide fibers5, (3) spiral-wound sheets of cellulose
acetate2, and (4) external coatings of Zr(IV)-PAA dynamically deposited7
on ceramic, 21 ran diameter tubes. The original program plan was to
evaluate only the polyamide and the Zr(IV)-polyacrylate membranes. The
project was extended since the four configurations represented basically
all the commercially available configurations.
The details operation performance of each membrane module evaluated
is presented in this section. The separation efficiency (rejection per-
centage) for the important parameters of oblor and specific conductivity
rejection and membrane flux are presented graphically for the entire
evaluation periods. The detailed chemical analyses and percentage re-
jection for each measured species are presented in Appendix C.
36
-------
PILOT PLANT
Figure 8 presents a schematic description of the pilot plant equip-
ment. The raw wastewater feed was introduced into the pilot plant either
from the total plant operation downstream of a 150 m3 level-controlled
mixing sump, or directly fron a dyehouse drain. The dyehouse drain led
fron only five (of 32) of the larger dye becks and was subject to wide
variations in composition ranging from that of the spent dye liquor to
that of comparatively clean wash water.
The raw wastewater was introduced into 2.3 m3 elevated reservoirs
through 40-mesh screen to remove participates, especially fibers. In
effect, the raw feed to the pilot plant was collected and processed as
2.3 m3 batches. Since the productivity and the capacity of the individual
hyperfiltration modules was not constant, the number of batches processed
per day varied.
The hyperfiltration membrane modules evaluated were of two basic
types. The modules with pre-formed membranes (polyamide and cellulose
acetate) were evaluated in a low pressure, up to 450 psi (3.1 x 106 Pa),
system employing a variety of prefilters, and temperature control (below
38 C). As required for cellulose acetate membranes, pH control was effect-
ed by monitoring and adjusting each 2.3 m3 batch. This system employed a
5.6 kW motor with a centrifugal pump (Gould BP3933).
The ceramic tube nodules (dynamic Zr(IV)-PAA membranes) were evaluated
in a high pressure loop, up to 1000 psi (6.9 x 106 Pa), employing a triplex
positive displacement Gaso pump with a 22 kW motor. Since no pretreatment
was required, it was possible to study the effect of prefiltration only by
by-passing feed fran the low pressure system downstream of its pretreatment
section.
For evaluation of the pre-formed membranes, the wastewater collected
in the 2.3 m3 elevated reservoirs was transferred by gravity to a 0.2 m3
pump suction reservoir. Before entering the membrane modules, the waste-
water passed through a prefiltration unit, which contained 25 micron and
1 micron cartridge filters in series. When required, the wastewater could
also be directed through a 2.2 m2 diatonaceous earth filter.
37
-------
u>
oo
TOTAL PLANT OPERATIONS
DYE HOUSE
BECK
*I9
40Om3/d
7460 m Vd
PILOT PLANT'
18m3
TORA
TANK
I "
PRESSURE SEWER
PRO
\
J >,
Pre-formed-'''
R.0vx"
x- ^Membranes
pH Contr. | ^^
S| r~S~
Heat 1 T 'A
lExch. /'
nilf.^ ^CONCENTRATE
^ /fim 3
\
(STORAGE J Dynq
XTANK^/ PRODUCT Mem
i i
' 25 /<
Md
M
Kcscnvuino
r\~L '
1
A
Ho. f
j. 1 !
". |
J
|
jnk
brdnes^
i
^
j,
40 MESH
SCREENS
Figure 8. Schanatic of pilot plant layout.
-------
instrumentation was included to permit monitoring of flow rates,
pressure, and feed temperature. Sampling ports were provided to
facilitate sample collection for monitoring module performance in
terms of water quality and concentration factors.
The product and concentrate from the hyperfiltration modules were
collected in stainless steel storage tanks. Generally it was necessary
to collect fron 1.5 to 3.8 m3 of concentrate and from 9.5 to 17 m3 of
product water to carry out a full scale production dye cycle in the
standard t*o-piece beck. The normal procedure was to do one reuse
dyeing per month. On occasion, two reuse dyeings were accomplished by
using the product and concentrate in separate full scale production dyeings.
TUBULAR CELLULOSE ACETATE (Westinghouse)
During the period from December 5, 1973, to February 1, 1974, a
Westinghouse tubular, cellulose acetate membrane module (No. 4-291) was
operated on total plant composite wastewater for 1059 hours. The unit was
used to process a total of 10.7 m3 of wastewater collected in four batches.
To simulate the operating conditions for a full scale treatment plant,
the module performance was monitored as the wastewater was concentrated
to product water recoveries of 96%. The first two batches, a total of
6.1 m3, were concentrated to an average recovery of 72%. The concentrate
and product waters were collected and used in a full scale dyeing (Cycle #10)
Independently, the last two batches, approximately 2.3 m3, each were con-
centrated to 96% recovery.
The module evaluated was a tubular configuration having 0.86 m* of
cellulose acetate membrane surface. The tubular flow passages consisted
of eighteen, 13 nm diameter channels in a porous cylindrical block, a
"sand log", enclosed in a 101 mm diameter by 1.22 m long stainless steel
pressure vessel. The fluid flews through each of these eighteen channels
in series.
Two operational modes were used. The first was the concentration
mode. In this mode, the product water from the module was collected for
reuse while the concentrate was directed back to the 0.2 m3 polyethelene
39
-------
tank at the punp suction. Raw feed was continuously added to this
tank from the 2.3 m3 elevated feed tanks so that the level in the
punp suction tank was constant. The concentration of the feed in the
test loop continuously increased as the product water was withdrawn.
The variation of concentration with time simulated the variation of
concentration with location in a full scale plant.
In the second mode, one 0.2 m3 batch of wastewater was recircu-
lated continuously through the module with both the product water and
the concentrate directed back to the pump suction tank. Except for
minor changes in the characteristics of the wastewater with time, this
recirculation mode was a steady state condition. This steady state
performance simulated the operating conditions of individual modules in
a full scale treatment plant.
The main operating parameters which were varied during the course
of the tests were the feed pressure upstream of the module, 300 - 450
psi (2.7 x 106 to 3.1 x 106 Pa), the supply temperature, 55 - 90 F
(12.8 - 32.2 C), and the circulation velocity, 5-10 ft/sec (1.5 -
3 m/sec). The operation of the loop was conducted on a continuous basis
except for maintenance downtime. When the loop was shut down, the module
was flushed with tap water for about 10 minutes in both the normal and
reverse flow directions.
Before any wastewater was supplied to the module, it was tested with
a solution of 500 mg/Jl NaCl in water. The results of 150 hours of
operation using the NaCl solution are shown in Figure 9. After an initial
decline, the product flux was constant at 8.3 GFD (0.023 on/min) for
a pressure of 300 psi (2,07 x 106 Pa), and temperature of 60 F (15.5 C).
The conductivity rejection averaged 91% for this salt solution.
The operating performance of the Westinghouse module is presented in
Figure 9, where the membrane flux, color, and conductivity rejections are
plotted for the initial 36 days of operation. Following the introduction
of wastewater to the module, on the ninth day, the flux dropped 15% as the
concentration of the feed was more than doubled by recovering 66% as pro-
duct water. Additional raw wastewater was mixed with this residual of
Batch #1 on the sixteenth day. Operation continued to 73% water recovery;
40
-------
g
i
UJ
oc
E
u
100
95
90
85
.03
.02
.01
O
COLOR -
CONDUCTIVITY /*
© © © '
©
WW-WATER WASH
O TAP WATER/SALT SOLUTION
& « PLANT COMPOSITE (filtered ,
DESIGN VALUE
FOR COST
PROJECTION
RECIRCULATION-f,
66% RECOVERY
Batch no: I
73%RECOVERY.fr
Batch no: I
SHUT
DOWN
2.7
46% RECOVERY-^
Batch no: 2
71%
tRECOVERY
Batch no: 2
10
15 20
DAYS
25
30
35
Figure 9, Operating performance of Westinghouse module at La France.
-------
i.e., about 4-fold concentration of the feed to the module, was accomp-
lished on the twenty-second day. During the processing of this combined
batch of wastewater, the flux decline increased. The flux had declined
nearly 40% as wastewater was processed to 73% recovery; from 0.023 to
0.014 cm/min. Both the conductivity rejection (95 - 91%) and color re-
jection (99+ - 98%), however, exhibited only slight decreases as the
concentration of the feed supply to the module was increasing.
Following the transfer of Batch #1 concentrate to storage, the
module was cleaned by flushing with tap (plant process) water for 15
minutes. Following shut down over the weekend, the flux was 0.02 on/torn
during the initial operation with Batch #2 wastewater. This was a re-
covery to approximately 90% of the flux with the salt water solution.
Wastewater Batch #2 was processed to slightly more than 71% recovery
during the period from the twenty-sixth day through the thirty-fifth day
of operation. During the next seven days as the feed to the module was
processed to about double its original concentration, the flux declined
rapidly to 50% of the original value. A 20-minute flush with tap water
only partially restored the flux. A second 20-minute tap water flush was
followed immediately by an increase in the operating pressure fron
2.07 x 106 to 3.1 x 106 Pa. The flux increased correspondingly to 0.027
cm/fain. With this high flux, wastewater Batch #2 was then concentrated to
71% product water recovery rapidly. No flux decline was noted during the
two-day operation at this elevated pressure. There was a significant
drop in rejections, however, color (99 - 95%), and conductivity (95 - 90%).
These results are tabulated in Table 13. The pH was maintained in
the range of 5.6 - 6.6. The total solids concentration of the two batches
of wastewater were 1380 mg/£ and 2265 rng/i. The total solids concentration
in the final mixed concentrate fron these two batches was 4000 mg/fc.
During the final 500 hours of operation of the Westinghouse module,
the parameters of velocity, temperature, and pressure were varied while
both the product water and concentrate were recirculated to maintain a
constant feed to the module. The recirculation prior to any concentration
of the raw wastewater feed simulated the inlet section of a treatment
plant. Recirculation after an initial period of recovery of 96% of the
42
-------
Table 13. OPERATING PERFORMANCE3 OF TUBULAR CEUULOSE ACETATE WESTINGHOUSE MXULE
WITH IA FRANCE COMPOSITE WASTEWMTER
10
Operating
time(hrs)
December 1973
1
23
95
143
185
337
January 1974
435
502
525
530
545
Flux
(on/tain)
(Pressure 2.07
0.023
0.020
0.018
0.016
0.016
0.014
0.014
0.011
(Pressure 3.1 x
0.027C
0.028
0.028
Total Solids
x 106 Pa)
-
97
96
96
-
-
97
96
106 Pa)
»
92
92
Rejections (%)
Color
-
99.7
99.9
99.3
99.0
98.7
99.9
99.9
99.9
93.2
93.2
Conductivity
92
95
95
93
92
91
94
94
95
88
88
Recovery
i Fraction (%)
0
_
_
_
66
73
27
46
46
-
71
Operating conditions held constant. Flow = 11 dm3/inin; pH = 5.8 - 6.9; T = 11 - 15 C.
Color 585 - 3960 Pt-Co units; total solids 1380 - 4155 rag/*/ conductivity 960 - 8500 yitiio/cm.
Tap water flush increased flux 0.11 to 0.18
-------
product water (corresponding to about a 20-fold increase in concentration
of the feed to the module) simulated the extreme outlet section of a
treatment plant.
The results are tabulated in Table 14, and illustrated in Figure 10.
The decline of flux and rejections with increasing concentration, as pro-
duct water recovery increased, is evident for both 2.3 m3 batches of
wastewater processed. The effects of pressure and temperature are as
expected. The sharp drop in flux that occurred at the end ,of the test
period is not understood.
In summary, the performance of the Vfestinghouse tubular cellulose
acetate module exhibited a 40% loss in flux for product water recoveries
of 75 - 90%. This result is reflected in the selection of a design con-
dition of 450 psi (3.1 x 106 Pa), which at a temperature of 90 F (32 C)
yielded a flux of over 0.042 on/min. The design value for these operating
conditions was taken as 0.038 cm/min for the cost projection. No deter-
gent cleaning was used in this study, however, this may prove practical
periodically, particularly in modules exposed to the higher concentrations
near the outlet of a treatment plant. The quality of product water at 75%
recovery was satisfactory for reuse in all dyeing operations at La France.
HOLLOW POLYAMIDE FIBER (DuPont)
During the period from February 6, 1974, to March 27, 1974, a DuPont
hollow-fine polyamide fiber module (No. 400600) was evaluated. During this
period the module was operated for 187 hours with a continuous fresh supply
of wastewater from five dye becks. The limited capacities of the specific
prefiltration available in the pilot plant made it possible to operate the
module only an average of about 4 hours per working day. However, the
module was used to process over 79 m3 of wastewater, the final portion of
which was reused in Cycle #12.
During the first several months of operation of the pilot plant, two
other DuPont modules were used to process total plant composite wastewater.
Even though the earlier processed wastewater was reused in plant dyeings,
Cycles #1 through #6, only the equipment performance evaluated during
44
-------
Table 14. OPERATING PERFORMANCE3 OF TUBULAR CELLULOSE ACETATE WESTINGHOUSE MODULE
WITH LA. FRANCE COMPOSITE WASTEWATER UNDER VARIABLE CONDITIONS
ui
Operating
time(hrs)
556
648
670
674
701
720
744
750
891
901
920
947
1010
1035
1059
Temperature
( C)
Pressure =
17
18
13
32
34
Flow = 11.
26
30
Pressure =
17
18
19
19
Pressure =
16
19
19
17
Flux
450 psi (3.1 x 106
.030
.025
.025
.044
.043
3 dm3/bin
.043
.045
Rejections (%)
Color
Conductivity
Pa); Flow = 22.7 dm3/min
99.3
98.9
99.5
99.7
94.7
97.0
97.1
92
93
95
93
85
92
91
300 psi (2.07 x 106 Pa)
.021
.012
.012
.012
450 psi (3.1 x 106
.024
.023
.018
.010
99.1
99.3
99.3
98.8
Pa); Flow
96.9
99.2
98.4
96.7
93
90
88
80
= 22.7 dmVnon
93
94
93
92
Recovery
Fr action (%)
0
62
73
79
97
19
45
45
96
96
96
0
0
0
0
, Operating conditions: pH = 6.0 - 8.0
Color 60 - 2085 Pt-Co units, conductivity 650 - 11,200 yitiho/cm
-------
*>.
COLOR
CONDUCTIVITY
PRESSURE, M Pa
VELOCITY, m/sec
TEMPERATURE,C
100
200
300
HOURS
400
500
Figure 10. Operating evaluation of Vfestinghouse module during final 500 hours.
-------
Cycle #12 is felt to be typical for the DuPont modules. The procedure
followed during Cycle #12 is: (1) Only dyehouse wastewater (to mini-
mize sanitary constituents) was treated, (2) only "fresh" feed entered
the module; i.e., no recirculation of wastewater, (3) no stagnant con-
ditions with wastewater in the modules were permitted, and (4) diato-
maceous earth prefiltration (prior to 25 micron and 1 micron cartridge
prefilters) was employed. These conditions limited the productivity of
the pilot plant which had limited prefiltration capacity. As indicated
in the cost projections for a full scale treatment plant, these procedures
have little effect on cost of plant operation.
These four operating procedures were followed as the module was
evaluated for a 20 dm3>in supply rate which at 350 psi (2.4 x 106 Pa) and
about 60 F (15.5 C) resulted in approximately a 50% recovery of water.
Only during the last 15 hours of operation was recirculation of processed
concentrate employed. At that time the initial concentrate was collected;
e.g., 1.2 m3 from each 2.3 m3 of dyehouse wastewater, and reprocessed, also
at 20 dm3/min and 50% recovery for in-plant reuse evaluation.
The details of the operation of the DuPont module are presented in
Table 15 and shown in Figure 11. The tabulated results indicate the waste-
water PH range was 6.2 - 8.0. No pH adjustment was required as the poly-
amide filers can operate in the range of pH 2 - 11. The temperature ranged
fron 11 C - 23 C.
Even though constant attention was required to maintain the proper
prefiltration, the pressure drop across the module did not exceed the
specified limit of 20 psi (0.14 x 106 Pa) until after approximately 166
hours of operation. Four hours of detergent washing reduced the pressure
drop to its initial level. As shown in Figure 11, the product flow rate
was reduced only slightly at the greater nodule pressure differential, and
was not significantly improved by the detergent washing.
In Figure 11, a very sharp decline in product flow that occurred at
65 hours of operation is noted. The total solids concentration of the
wastewater supplied to the module was 16,000 rng/u other declines in
product flow rate occurred at 30 hours and at 187 hours. At both of these
times the total solids were higher than the average of about 2300 mg/A;
47
-------
Table 15. OPERATING PERFORMANCE3 OF HOLLOW POLYAMIDE FIBER DUPONT MODULE
WITH LA FRANCE DYEHOUSE WASTEWATER
oo
Operating
time(hrs)
February
1
10
16
23
27
32
48
64
65
73
81
106
129
144
160
166
Tenperature Product Flow Rate
( C) dm3/tain
1974
19 9.0
14 8.0
11 7.9
20 8.3
17 8.3
9 6.4
13 8.3
14 3.8
18 3
11 7.6
12 7.9
19 8.0
23 7.9
18 7.9
20 7.6
16 6.8
Rejections (%)
Color Conductivity
>99 96
98 97
93 94
>99 98
>99 97
>99 96
>99 97
>99 92
93
95
>99 97
>99 94
>99 93
>99 88
>99 94
>99 91
Recovery
Fraction (%)
53
49
47
49
49
56
49
22
18
44
47
49
47
47
44
40
March 1974 (shut down for detergent wash)
172
176
180
187
12 6.4
16 6.8
18 7.6
20 6.4
>99 89
98 82
>99 84
>99 86
50
50
50
50
, Operating conditions: P = 2.4 x 105 Pa; flow
Color 30 - 1250 Pt-Co units; conductivity 610
17 dm3/kLn; pH = 6.2
22,000 umho/on.
- 8.0.
-------
100
2 80
uj
C
E
E
o
O
u
TO
COLOR
CONDUCTIVITY
BIZ-WASH
TOTAL SOLIDS
16,OOO
DESIGN VALUE FOR
COST PROJECTIONS
I
E
o
w
1 1 1 1 i i i i
20 40 60 80 100
HOURS
120
140
160
190
Figure 11. Operating performance of DuPont hollow polyamide fiber nodule at La France.
-------
i.e., 4515 mg/£ at 30 hours and 3400 mg/£ at 187 hours. There is
evidently a significant effect on product flow rate of high solids load-
ing, even after extensive prefiltration. It does appear that the effect
is easily reversed by returning to a lower solids concentration. The
effect of total solids concentration upon the rejections is quite small.
Following the wash with Biz detergent at 166 hours, the wastewater
was recirculated to achieve a constant 50% product water recovery. This
recirculation was continued for only 15 hours, but seemed to influence
both product flow rate and rejection. The conductivity rejection de-
creased from 90 to 85%, while the product flow rate increased by 17%.
Following the Biz detergent wash, 1.2 m3 of concentrate was collected
while the module was operating at 50% product recovery. When this con-
centrate was returned to the module as feed, the product flow rate dropped
by 10%, and the conductivity rejection increased slightly. (The data are
shown as the last data points in Figure 11.)
There is no apparent explanation for these trends. It seems worth-
while to conclude, however, that while detergent washing was effective in
reducing the pressure differential across the module, the washing had no
significant effect on either product flow rate or rejections.
In summary, the performance of the DuPont hollow fiber module was
evaluated for 187 hours. With filtered dyehouse wastewater fed continuous-
ly to the module, and with no recirculation of concentrate, the pressure
differential across the module exceeded desired limits after 166 hours of
operation. It is possible that the daily re-charging required for the
small diatomaceous earth filter allowed particulates to enter the module
which could account for the pressure differential build-up. ABCOR used
the above data to prepare the cost projections for a full scale treatment
plant. The cost analysis included prefiltration as recommended by EuPont.
The quality of the product water fron the DuPont module was adequate
for reuse in all dyeing operations at La France.
50
-------
SPIRAL-W3UND CELLULOSE ACETATE (Gulf)
During the period fron March 28, 1974, to May 7, 1974, a spiral-
wound, cellulose acetate membrane module was evaluated. During this
interval the module was operated for 632 hours on wastewater supplied
from fxve dye becks and subsequently for 172 hours on composite waste-
water fron the total plant. The unit thus processed approximately 230 m3
of wastewater. A portion of the approximately 45 m3 of composite waste-
water processed was stored for reuse in dye Cycle #14.
The module evaluated contained 3 standard spiral-wound units in a
101 rnn diameter x 3.65 m long pressure vessel. The membrane surface area
was 18 m2.
During the evaluation, the module was supplied with 13 dm3/min of
25 micron prefiltered wastewater and operated at 400 psi (2.76 x 10* Pa)
in the temperature range of 14.4 - 25.5 C. The initial product water flow
rate was 4.5 dr^n yielding 33% product recovery. After about 90 hours
of operation a portion of the module effluent was recalculated directly to
the pump suction to maintain a 75% recovery. The PH was controlled in the
range of 5.8 - 7.0, except for brief exposures to PH 8. PH control was by
chemcal addition to each 2.3 m3 batch of wastewater processed.
The operating performance of the Gulf module is shown in Figure 12,
and Table 16. The product flow rate, color, and conductivity rejections
are plotted for the entire period of the evaluation. The product flow rate
decreased fron an initial value of 6.7 dm3>in exhibited during the treat-
ment of a 1500 mg/£ NaCl solution to a stable value of 3 dm3/min.
The variations in prefiltration, wastewater source, and mode of
operation did not seem to materially influence the membrane performance
The performance over the last 170 hours of operation with 25 micron pre-
filtration, while processing cotposite wastewater to 75% product recovery,
was used as the basis for the cost projections.
The color rejection was uniformly greater than 99%. The conductivity
rejection averaged approximately 95%. The slight decrease in conductivity
rejection, shown in Figure 12, is apparently related to higher total solids
concentration in the wastewater.
51
-------
Table 16. OPERATING PERFORMANCE3 OF SPIRAL CELLULOSE ACETATE GULF MODULE
WTTH LA FRANCE WASTEWATER
Operating
time(hrs)
Product Flow Rate
dm3/fran
Rejections (%)
Color Conductivity
Recovery
Fraction (%)
March 1974
1
20
1
20
91
April 1974
95
120
146
165
193
259
272
440
630
(1500 mg/A NaCl)
6.4 - 95 37
6.4 - 96 37
(dyehpuse wastewater, 1 micron filter)
4.5 97 97 33
4.2 97 98 32
3.8 98 98 29
4.5 99 97 75
4.5 99 97 75
4.5 99 97 75
(dyehouse wastewater, 25 micron filter)
4.5 99 96 75
4.5 99 96 75
4.5 99 93 75
(closed circuit recycle started)
3.0 99 95 75
3.0 99 95 75
3.0 99 93 75
(end recycle - 1 hour tap water flush)
(composite wastewater - collection for dye Cycle #14)
633
May 1974
660
708
780
3.8
3.0
3.0
3.0
99
99
99
99
97
97
97
97
75
75
75
75
, Operating
Color 57
conditions: P = 2.8 x 106 Pa; Flow = 19 dm3/inin; T
2800 Pt-Co units; conductivity 1450 - 5900 pinho/cm,
=14-26 C; pH = 5.8 - 7.0.
-------
100,.
COLOR (> 99%
CONDUCTIVITY
ui
u>
XD
O TAP WATER/SALT SOLUTION
6
5
4
c
5 »
o
I .
u.
PRODUCT
O _
.
1
1
33%^ ^7*1
% WATER
^^_
lju ^
V* ^
FILTERS
FRESH F
yi
?EED
TO MODULE
RECOVERY
.. . . .\
DYE HOUSE WASTEWATER
COMPOSITE WASTEWATER
DESIGN VALUE
FOR COST
PROJECTION
RECIRCULATION OF 0.2m3 fc- FRESH FEED
OF WASTEWATER TO MODULE
IOO 200 300 4OO 500
HOURS
600
700
800
Figure 12. Operating performance of Gulf (U.O.P.) spiral cellulose acetate module at La Francs
-------
In sunmary, the Gulf spiral-wound cellulose acetate module exhibited
a flux decline of approximately 40% for treatment of composite wastewater
to 75% recovery of product. The product flow rate was stable over an
extended period of operation. The quality of product water was satisfactory
for reuse in all dyeing operations at La France.
DYNAMIC Zr(IV)-POLYACRYLlC ACID (Selas)
During the period June 4, 1974, to July 2, 1974, a Selas ceramic
tube, Zr(IV)-polyacrylic acid membrane was operated for 650 hours. The
unit was evaluated first with wastewater from five dye becks and then with
the composite wastewater from the total plant. In addition, the membranes
were used in a separate evaluation of indigo wash water. The concentrate
from the treatment of the dyehouse wastewater was reused in Cycle #16.
The module evaluated was a tubular configuration employing eight units
in series. Each unit consisted of 19, 5.5 mm diameter porous ceramic tubes.
The membranes were deposited on the external surface of the tubes. With
a 0.16 m3/min wastewater supply rate to the module, the ratio of product
water or permeate flow to wastewater flow through the module was consider-
ably less than 1%.
Two modes of operation were used. The first was the concentration
mode. In this mode of operation product water from the module was collect-
ed while the concentrate was recirculated to a 0.3 m3 stainless steel tank
at the pump suction. Raw wastewater was continuously added from the
2.3 m3 elevated reservoir to maintain a controlled level in the 0.3m3
tank. The concentration of the feed to the module continuously increased
as the product water was withdrawn. In the second mode of operation, one
0.3m3 batch of wastewater was recirculated continuously through the
module with both the product water and concentrate directed back to the
punp suction tank.
The operating parameters varied during the course of the evaluation
were: (1) type of wastewater, (2) degree of prefiltration, (3) pres-
sure, 300 - 700 psi (2.07 x 106 to 4.8 x 106 Pa), (4) temperature, 80 -
190 F (26 - 88 C), and (5) circulation velocity, 2.3 - 4.6 m/sec. The
54
-------
PH was not controlled, sinoe dynamic nentoranes can operate in a range of
PH 4 - 11, well within the range observed for the wastewater at La
France.
Previously, dynamic membranes in laboratory test nodules provided
by the Oak Ridge National Laboratory were used to provide the renovated
wastewater reused in Cycles #7, #8, and #9. since these test nodules
were not ccmnercially available, only the performance of the Selas module
is considered appropriate for use in the cost projections.
Before any wastewater was supplied to the Selas nodule, it was test-
ed with a 500 mgA Nad solution. At 700 psi (4.8 x 10* Pa) and 50 C
the flux was 0.33 cm>in ^ ^ conductivity ^^^ wafi gi%> ^
operating performance of the Selas nodule is described in Figure 13, and
TabJe 17, where the flux, color, and conductivity rejections axe presented
for 30 days of operation. To evaluate the effect of wastewater conposition
and prefiltration on the rate of flux decline, the nodule was evaluated
under what was expected to be increasingly more difficult conditions.
Because the characteristic of high temperature operation permits the
possibility of energy recovery, the tests were carried out at elevated
temperatures.
Initially, the nodule was supplied with wastewater fron five dye becks
This wastewater was prefiltered through the 25 micron cartridge filters.
The flux declined sharply from greater than 0.33 cm/min to 0.045 cn^min!
Subsequently, a flush with tap water returned the flux to 0.1 cm/min. A
repeated concentration of dyehouse wastewater to about 75% product recovery
produced a similar decline in flux to about 0.055 cm/min. Another flush
with tap water resulted in a flux of about 0.1 cm/min.
A series of tests with indigo rinse water was carried out from the
fourteenth to the twenty-first day. During this tine the flux recovered
to over 0.22 cm/min. ^ sharp drop in conductivity rejection that occur-
red on the seventeenth day corresponds to a total solids concentration of
57,000 mg/Jl.
Beginning on the twenty-first day, the module was then supplied with
total plant composite wastewater through 25 micron prefilters. The flux
decline was again rapid. After about 20 hours, the module supply was
55
-------
Table 17. OPERATING PERFORMANCE3 OF CERAMIC TUBE Zr(IV)-PAA SELAS MODULE
WITH LA, FRANCE WASTEWATER.
en
ov
Operating
time(hrs)
June 1974
22
Flux Temperature
(cm/min) ( C)
(salt solution)
.34 50
Reiections
Color conductivity
91
(dyehouse wastewater, 25 micxon filter)
30
76
98
148
.23 43
.05 46
.04 48
(salt solution)
.10 36
>99 83
>99 88
88 87
92
(dyehouse wastewater, 25 micron filter)
167
190
238
262
330
338
356
375
402
497
.07 30
.12 48
.07 48
.06 48
(tap water)
.12 54
(indigo)
.13 58
.15 60
.12 46
.16 60
.29 55
>99 89
>99 88
97 ' 88
95 86
_ _
91
>99 88
>99 88
>99 61
>99 87
(composite wastewater, 25 micron filter)
502
518
535
571
.23 55
.12 57
(composite wastewater, 250 micron)
.16 53
.13 58
97 80
98 81
>99 80
>99 75
f* Operating conditions: P = 4.8 x 10s Pa; Flow = 0.15 m3/friin.
Color 715 - 19,575 Pt-Co units; conductivity 960 - 36,650 nmho/cm.
-------
100
90
a?
- 80
t 70
u
s *rt
a: 60
O
£
u
.4
AA
O O
DA A COLOR
cAA A A A CONDUCTIVITY
D
O TAP WATER/SALT SOLUTION
DYE HOUSE WASTE(filtered,25/<)
A INDIGO WASH (Concentrating)
A INDIGO (RECYCLE)
PLANT COMPOSITE(filtered,25/<)
D PLANT COMPOSITE (filtered, 25O/<)
DESIGN VALUE FOR
COST PROJECTION
02466
Figure 13. Operating performance of Selas dynamic membrane module at La France,
10 12 14 16 18 20 22 24 26 28 30
DAYS
-------
changed to total plant composite wastewater, through only 250 micron
prefliter. For 55 hours the flux remained at about 0.11 cm/roin. The
evaluation was concluded with a period of 90 hours of operation with
recirculation of indigo rinse water. The flux remained stable at
0.14 on/nin.
Throughout the period of evaluation, the color rejection remained
near 99%. The conductivity rejection decreased gradually frcm about
90 to 80%. This membrane has subsequently been exposed to a variety
of dye wastewaters and retains these percentage rejections after about
4000 hours of operation.
In surtmary, the dynamic membrane operating performance exhibited a
characteristic of quick accormodation to particular feed conditions.
The design value for the treatment plant cost projection was 0.14 cm/tain
based on 950 pai (6.5 x 106 Pa) operation, which corresponds to a value
of 0.11 cm/min based on the performance data at 700 psi (4.8 x 106 Pa)
and 50 C. The performances indicate best operation on unfiltered (ex-
cept for 40-mesh screening) total plant conposite wastewater. The
quality of the product water was satisfactory for reuse in all dyeing
operations at La France.
DESIGN VALUES FOR COST PROJECTIONS
The operating performance data obtained during the pilot plant pro-
gram form the basis for the cost projections for a 7570 m3/day treatment
plant. The four membrane modules were evaluated within the manufacturers
recomended operating limitations. The parameter of primary importance
in the cost projections is the membrane flux, i.e., the product water flow
rate per module. The long-time membrane flux, estimated from the test
data, is listed in Table 18. In the case of the hollow fiber polyamide
membrane, the estimate of long-term flux is 20% below the value observed
during the relatively brief operating time during the pilot plant program
(less than 200 hours).
The membrane flux is directly dependent upon the operating pressure
and is strongly influenced by the operating temperature . Both the pilot
58
-------
Table 18. MEMBRANE FLUX FOR OOST PROJECTIONS
vo
MEMBRANE
MODULE
CCNFIGURATICN
PILOT PLANT RESULTS
Pressure, M Pa
Temperature, C
Flux, cnymin
DESIGN VALUES
Pressure, M Pa
Temperature , C
Flux, cm/min
Polyamide
hollow fiber
2.4
21
0.004a
2.4
32
0.005
Cellulose
Acetate
spiral-wound
2.8
21
0.017
2.8
30
0.020
Cellulose
Acetate
tubular
2.1
16
0.017
2.8
30
0.028
Dynamic
Zr(W)-PAA
tubular
4.8
50
0.15
5.2
45C
0.15
20% reduction from value measured at less than 200 hours operation
Temperature effects based on manufacturers data.
Thermodynamic mean temperature of plant effluents.
-------
plant test values ard the design values of pressure and temperature to
be used in the cost projections are tabulated in Table 18. The design
value of flux for each membrane module configuration, in Table 18, is
thus the valve measured in the pilot plant corrected to the design
temperature and pressure.
60
-------
SECTION VIII
TRES3MEOT ELROT COOT PEOGECTIONS
ae equips perform^ data detsrndned in the pilot plant in-
vestigation are used in the follo^ ^ projections for . .
oecons or . ^.
gallons per day ,7570 m'/day, hyperfiltration treats plant for the
"" 1»~ *«" ~ at-nt, i.e., pH
control, arf suspend solids
f a°- H-ver, no allo, is
for storage reservoirs, nor for the 10 - 20* *^ water
-
nor for treataent of any retired bio, do of concentrate.
Ihere is a wide variation in both the capital cost and operating
costs a^ong the four .M. systaje. ^ ^^ ^^ ^ ^
poly^ and cellulose aoetate ^rbran, system is for ^toane replace-
ment. ae ra:0r operating cost for the dynamic ,,3*^ vstem is
etectrical pc^er for punping. ae major capital cost for all the systems
is for the mambrane modules.
ae polye^dde and spirals* ^ ^^ ^^
are of interest for water treataent applications because of their relative-
ly lor capital and operating costs. They generally require fine pre-
fitoauon heaver. ^^ ^^ ^^ ^^ ^
high *»! capital cost, but are saIEwhat easier to cerate since they
re^re only relatively coarse prefiltration. The tubular
. r nanes
relatively easier to mechanically clean, a possibly significant advantage
for so^ industrial applications. a» dynaMc ZrflVJ-PM mitlmm ^
a relatively high initial cost, but require the least prefiltraticn. a.
aa^ntage of high temperature operation (to 100 c, precludes pretreafcj
ten^ature oontro! requirenants « may, t^h recycle of L water,
permit significant energy conservation.
THE TREATMENT SYSTEM
A schematic materia! balance for the treatnsnt of
by hyperfiltration is she in figars M.
61
-------
FEED VOLUME- 7575 m3/day
FEED COMPOSITION
TOTAL SOLIDS" 100 to SOOOmgA*
COD = 20O to 300 mg /A
COLOR » 3OO to 600 Pt-Co Units
a\
NJ
PRETREATMENT
CONCENTRATE WATER
For Dyebath Use
VOLUME" I5l5m3/day
TOTAL SOLIDS » 7,OOO to I5,000mg//
COD - 350 to 550 mg/*
COLOR = 6OO to I ZOO Pt_Co Units
HYPERFILTRATION
MODULE UNIT
PRODUCT WATER
Reuse for Plant Water
VOLUME = 6O60 m3/day
TOTAL SOLIDS" 100 to 6OO
COD ° 25 to 50 mg ft
COLOR = 20 to 50 Pt-Co Units
Figure 14. Simplified flow schematic of a textile dyewaste treatment system.
-------
at a rate of 2^nillion-gallons per day (7570 mVday) is processed through
a pretreatatent section. The pretreatment section may consist of equipnant
for PH adjustment, coarse and/or fine filtration to remove suspended
matter, and heat exchangers to cool the feed stream to about 32 c, the
normal operating temperature for the pre-forned membranes.
As shown in Figure 14, 80% of the wastewater feed will be recovered
as product (desalted and decolored) by the hyperfiltration unit, and re-
cycled to the textile plant for use as process water. The concentrate
will be recycled to the dyeing prooess for salt and/or dye reuse. The
point of recycle mst be determined by the chemical exposition of the
concentrate stream and the details of the dyeing prooess.
The complete and continued recycle of wastewater within the textile
mill may cause a gradual build up of impurities in the prooess water. If
the level of impurities reaches an undesirable level, there must be a
blow down of some concentrate fron the system. Selection of a treatment
method for the concentrate must be determined for the particular waste-
water. Wastewater or blew down disposal fron the hyperfiltration plant
has not been included in the plant design presented here.
EQUIPMENT DESCRIPTION AND CAPITAL COST PPOJBCTIQNS
Four capital cost estimates for full seals hyperfiltration treatment
plants are presented. Each deals with a particular membrane configuration.
Case 1 involves the hollow fiber polyamide membranes (DuPont); Case 2 in-
volves the spiral^ound cellulose acetate membranes (Gulf); Case 3 involves
tubular cellulose acetate membranes (Vfes tollhouse); and Case 4 involves
dynamic membranes (Selas). Cost and characteristics for the four types
of membrane modules are given in Table 19. Costs of pumps and filters
are based on quotations f ran vendors and other equip*** costs and estimated
in 1975 prices.
The cost projections are developed for the hyperfiltration module
unit and then for the pretreatment units separately. The cost projections
for the total plant are obtained by combining the costs of these two
major units with auxilliary equipment and engineering costs
63
-------
Table 19. MEMBRANE MODULE CAPITAL COST BASIS FOR PROJECTIONS
MEMBRANE
CONFIGURATION
MODULE DIMENSIONS,
Diameter x Length, m
MEMBRANE AREA, m2
DESIGN PRODUCT FLOW,
dm3 /tain
OPERATING PRESSURE,
M Pa
FEED RATE, dm3/min
PRESSURE DROP, M Pa
BARE MEMBRANE COST
HOUSING AND ASSEMBLY
Polyamide
hollow fiber
0.2 x 1.2
603
32
2.4 - 2.8
49
0.14
$2500
$1000
Cellulose
Acetate
spiral-^wound
0.2 x 1.0
28
5.8
2.4 - 2.8
189
0.27
$665
$1200
Cellulose
Acetate
tubular
.15 x 1.8
2.6
0.7
2.4 - 2.8
340
0.14
$271
$230
Dynamic
Zr(IV)-PAA
ceramic
0.07 x
0.8
1.2
6.5
227
.10
<1
$585
tubes
0.9
-------
Hyperfiltration Module Unit Cost Projections
The cost projection for the hyperfiltration module unit are
tabulated in Table 20. The specific characteristics of the design for
each menbrane nodule configuration are individually discussed as Cases 1
through 4.
CaseJ. - The membrane module product flow rate depends on membrane life
and cleanliness. Although new polyamide membrane nodules will yield
about 37 dm3>in of product per nodule, the plant has been sized for
32 dmVmin per nodule. If the product flow rate is too high initially,
it can be controlled by decreasing the operating pressure of the
system. Three-and-one-half percent extra membrane area has been pro-
vided for operation during membrane cleaning for emergency situations.
The hollow fiber nodule requires periodic back-flushing and cleaning.
It is assumed that enough product will be available to back-flush and
forward-flush every module for at least two hours per week. This will
require about 163 m3/day of product water. The plant size is augm-nted
to 7774 m3/day. Thus the number of nodules required is given by the
ratio of the plant size to the product flow rate multiplied by the per-
cent product recovery, i.e., 134 modules. Ten extra nodules are included,
bringing the total to 144.
The 144 polyamide membrane modules are incorporated into 16 parallel
banks consisting of two stages per bank, as shown in Figure 15. Each
bank consists of nine modules. The first stage of each bank includes
six modules in parallel. The second stage has three nodules in parallel.
Fifteen of the 16 banks must operate at all times while one may be idle
for maintenance or cleaning.
Each module requires 49 dm3/tnin of wastewater feed. The total flow
of 331 dmVmin through each module bank, once through both stages one and
two, will yield 80% product water recovery. The concentrate and product
effluents from each bank will be monitored by flow indicators. They are
designed to be 66 dm3/toin and 265 dm3/tain, respectively.
For equal distribution of wastewater flow through the parallel, a
65
-------
o\
FLUSH TO FEED
©
, ^ »
) PUMP
TO C
Fl i i^w TT» PFP n
x~x
* CPJ
T V*/
1 1
4OOosi
(2,7 M Po )
ITHER BANKS
- 9
- 9
- 9
B Q
S»
B_ Q
y
BA
9
1
T
4
1 II
1 II
I II
(ii
ft
1 II
-44
i ii
\ 9
1
B - !
;
»
9
\
y
1
7
1 II
1 H
1 II
i II
1 II
i II
CONCENTf
r^ -^
PRODI
,
KEY
B-9 DUPONT
P - PRESSURE GAUGE
Figure 15. Case 1 - Details of a meirbrane bank design.
-------
flew balancing resistance equivalent to 0.137 x 10* Pa pressure differ-
ential is incorporated at the discharge of each module. Whenever the
pressure drop across any stage becomes high and/or the product flow
rate of any bank drops below a set limit, the membrane bank in question
is isolated and cleaned.
High flew at low pressure are necessary for efficient nodule clean-
ing. A separate cleaning punp in a quick^isconnecting piping system
are provided for cleaning. The details of the pumping requires
for the modules are included in Table 20, with the suntnary of character-
istics and costs of the hyperfiltration module unit. Cost projections
for the pumping station required to flush, or clean, the module are also
included. The cost projections for piping and installation, electrical
serves, and instrunentation required for the hyperfiltration membrane
unit are the same for each membrai* type. These are also tabulated in
Table 20.
Casej. - The design product flow rate per module is based on the pilot
plant results. At the pilot plant test conditions, the membrane flux
in the spiral^ound module was measured as 0.017 cm/min. This flux
corresponds to a product flow rate of 5.8 dmVmin per module under the
design pressure of 2.7 M Pa and temperature of 30 C. Therefore, 750
modules in 125 pressure vessels yields 82.7% product water recovery
This provides for 204 m3/day for module flushing.
These 125 pressure vessels are incorporated into three stages. The
first stage will contain 504 modules, the second 162 modules, and the
third 84 modules. A tapered arrangement of modules, similar to that
shown in Figure 15, is employed. Six modules, and one pressure vessel
assenbly may te idle for maintenance or cleaning. A separate cleaning
pump is provided for cleaning.
The details of the pumping requirements for the modules are included
in Tabl* 20, with the suitmary of characteristics and costs of the hyper-
filtration nodule unit. Cost projections for the pumping station required
to flush, or clean, the module are a!so included. The cost projections
67
-------
Table 20. DETAILS OF CAPITAL COST PROJECTIONS FOR HYPERFILTRATION MODULE UNIT
(7570 m3/day & 80% Product Recovery)
CASE NUMBER
MEMBRANE MODULES
Configuration
Number
Cost, $
Maiibrane Cost
Included
PUMPS
Flow, m3/tain
en Head, M Pa
00 Power, kW
Cost, $
CLEANING STATION, $
PIPING COST, $
ELECTRICAL AND
INSTRUMENTS
TOTAL COST, $
1
hollow fiber
144
504,000
360,000
5.3
2.4
410
75,000
17,400
150,000
100,000
846,400
2
spiral-wound
750
648,750
498,750
5.3
2.7
410
75,000
17,400
150,000
100,000
991,150
3
tubular
5932
2,971,932
1,230,000
5.3
2.7
745
75,000
17,400
150,000
-
100,000
3,314,332
4
ceramic tube
3600
2,109,600
3,600
5.3
6.5
2600
337,124
17,400
150,000
100,000
2,714,124
-------
for piping and installation, electrical services, and instrumentation
required for the hyperf iltration membrane unit are the sane for each
membrane type. These are also tabulated in Table 20.
3 ~
design product flow rate per module is based on the pilot
plant results. For the pilot plant test conditions, the cellulose
acetate membrane flux for the tubular configuration was measured as
0.017 cm/min. This flux corresponds to a product flow rate of
0.7 dm3/toin per module under the design pressure of 2.7 M Pa and temp-
erature of 30 C. Therefore, 5933 modules are required to provide 82.1%
product water recovery. This provides 159 m3/day for module flushing.
A tapered arrangement of modules, similar to that shown in Figure 15,
is employed. Additional horsepower is required for recirculation of
feed to provide the required flow rates per module.
The details of the pumping requirements for the modules are included
in Table 20, with the summary of characteristics and costs of the hyper-
filtration module unit. Cost projections for the pimping station required
to flush, or clean, the module are also included. The cost projections
for piping and installation, electrical services, and instrumentation
required for the hyperf iltration membrane unit are the same for each
membrane type. These are also tabulated in Table 20.
4 ~
design product flow rate per module is based on the pilot
plant results. For the pilot plant test conditions, the dynamic Zr-
polyacrylate membrane flux was measured as 0.15 cm/min. This flux corre-
sponds to a product flow rate of 1.2 dm3/mirt per module under the design
pressure of 5.2 M Pa and temperature of 45 C. Therefore, 3600 nodules
are required to provide 82.1% project water recovery. This provides
159 m3/day for module flushing.
A tapered arrangement of modules, similar to that shown in Figure 15,
is employed. Additional horsepower is required (1) to pressurize the
feed to 950 psi (6.5 M Pa) , and (2) to recirculate feed to provide the
required flow rate per nodule.
69
-------
The details of the pimping requirements for the nodules are included
in Table 20, with the sunmary of characteristics and costs of the hyper-
filtration module unit. Cost projections for the punping station required
to flush, or clean, the module are also included. The cost projections
for piping and installation, electrical services, and instrumentation
required for the hyperfiltration membrane unit are the sane for each
membrane type. These are also tabulated in Table 20.
Pretreatment Unit Cost Projections
The cost projections for- the pretreatnent unit are tabulated in
Table 21. The specific characteristics for each membrane module con-
figuration are individually discussed as Cases 1 through 4.
In general, pretreatment costs are not a large part of the total costs
for the complete hyperfiltration system. The iitproved performance of the
membrane modules often effects savings to offset pretreatment expenditures.
The design case for each module configuration includes the pretreatment
recoimendations from the general experience of the manufacturers and the
pilot plant results for operation with La France's textile wastewater.
It was beyond the scope of this project to optimize the pretreatnent.
Case 1 - Based on the pilot plant experience with both total plant com-
posite and segregated dyehouse wastewater, the hollow polyamide fiber
membrane modules require very fine prefiltration, and wastewater cooling
to 32 C. Even though not required in the pilot plant tests, pH control
is included in the cost projections.
Based on the pilot experience, the hollow polyamide fiber module is
very sensitive to wastewater feeds containing collodial solids below 1
micron in diameter. Depth-type cartridge filters, 1 micron size, were found
to be insufficient in preventing hollow fiber module plugging during pro-
longed operation with the total plant composite wastewater. Segregated
wastewater from the dyehouse, after filtration through a pre-coat system,
could be processed for about 200 hours without substantial module plugging
substantial increase in module pressure loss), or deterioration in
70
-------
Table 21. DETAILS OF CAPITAL COST PROJECTIONS FOR PPETREATMENT UNIT
(7570 m3/day & 80% Product Recovery)
CASE NUMBER
MEMBRANE
CONFIGURATION
PREFILTER
Type
Removal
Cost* $
COOLING TOWER
Utilized Power, kW
Range, C
Cost, $
pH CONTROL
Cost, $
TOTAL PRETREATMENT, $
1
Polyaraide
hollow fiber
pre-coat
(<1 micron)
123,950
75
13
220,000
8,000b
351,950
2
Cellulose
Acetate
spiral-^wound
rotary screen
(>25 micron)
35,000
85
15
240,000
8,000
283,000
3
Cellulose
Acetate
tubular
rotary screen
(>25 micron)
35,000
85
15
240,000
8,000
283,000
4
Dynamic
Zr-PAA
external
tubular
screen
(>250 micron)
25,000
a
8,000b
33,000
, Dynamic membranes require no temperature control.
Polyamide and dynamic Zr-PAA membranes have pH ranges of 2
- 10 and 4-10, respectively.
-------
membrane flux or rejection. Consequently, a pre-coat (leaf) filter
is included in this Case 1 design.
Diatonaceous earth pre-coat was used in the pilot plant. Other
similar filter-aid material is expected to be equally effective. The
use of wood flour is assumed in this design.8 The cost projection in-
cludes all the necessary equipment to handle 453 kg as body feed to
50 mg/H. The cost projection is $123,950 for this prefiltration.
A cooling tower is designed to reduce the wastewater feed tempera-
ture to 32 C. The maximum operating temperature of the hollow fiber
module is 35 C. The cooling tower basin also serves as a feed surge tank
and a mixing zone for pH adjustment and any required water treatment
chemicals. Since the mixed temperature of the hot and cold dyehouse
effluents is 45 C in the summer, the cooling tower must provide a cooling
range of 13 C. The cooling tower and auxiliary equipment cost projection
is $220,000.
Case 2 - Based on the pilot plant experience with total plant composite
wastewater, the spiral cellulose acetate membrane modules require (1)
25 micron prefiltration, (2) wastewater cooling to 30 C, and (3) pH
control to pH 3 - 6.
During the pilot plant evaluation, depth-type cartridge filters,
25 micron size, were sufficient in preventing performance deterioration
of the spiral-wound module. A rotary screen filter is included in the
cost projection.
The cooling requirements for cellulose acetate membranes are similar
to those for the polyamide fdJxsrs. The reccrmended temperature is 30 C
for cellulose acetate, so the cooling range on the cooling tower is 15 C.
The cooling tower and auxiliary equipment cost projection increased
$20,000 from the Case 1 estimate because of the higher cooling load.
The acceptable range for operation of cellulose acetate at the
temperature of 30 C is pH 3 - 6. PH control is required for the La France
textile wastewater that averages nearly PB 1, but has peaks up to PH 10
or more.
72
-------
Case 3 - Based on the pilot plant experience with total composite waste-
water, the tubular cellulose acetate membrane modules require (1) 25
micron prefiltration, (2) wastewater cooling to 30 C, and (3) pH
control to pH 3 - 6.
These are the same requirements listed for the spiral module. How-
ever, since previous experience suggested finer prefiltration, these
cost projections include a 25 micron rotary screen filter.
The cooling requirements and pH control are exactly the same as
for Case 2.
Case 4 - Based on the pilot plant experience with both total plant com-
posite aid segregated dyehouse wastewater, the dynamic Zr-EM. mcdbles
require only coarse (>250 micron prefiltration). In fact, performance
with only this coarse prefilter was actually superior to that observed
with depth-type cartridge filters, 25 micron size.
No wastewater cooling nor pH control was needed in the pilot plant.
Since this membrane can operate at elevated temperatures, it is desirable
to take advantage of increased flux. The cost of PH control is included
since there was some indication of optimal performance at PH 8.5 - 9.5
that might make pH adjustments desirable.
Capital Cost Projections Summary
The total capital cost projections include auxiliary equipment and
services common to systems, independent of the type of membrane module.
The two main items are (1) a building to house equipment and controls,
and (2) the engineering services (including design, equipment procurement,
construction, supervision, and start-up).
The capital cost projections are summarized for each of the four
cases in Table 22. The principal differences among the four cases are, of
course, in the cost of the membrane modules. There are also major diffe-
rences among the costs of required pretreatment. The cost of the auxiliaries
are the same except for Case 3 (Westinghouse). In Case 3 the engineering
costs are considered part of the module cost.
73
-------
Table 22. CAPITAL COST PROJECTION SUMMARY FOR HYPERFILTRATION TREATMENT OF LA FRANCE WASTEWATER
(7570 m3/day & 80% Recovery)
CASE NUMBER
PRETREATMENT UNIT, $
MEMBRANE MODULE UNIT, $
AUZILIARY EQUIPMENT, $
ENGINEERING, $
TOTAL, $
CONTINGENCY (10%), $
TOTAL CAPITAL, $
MEMBRANE COSTS INCLUDED
IN CAPITAL, $
UTILIZED HORSEPOWER
1
351,950
846,400
117,500
300,000
1,615,850
161,585
1,777,435
360,000
585
2
283,000
991,150
117,500
300,000
1,691,650
169,165
1,860,815
498,750
595
3
293,000
3,314,332
117,500
a
3,714,832
371,483
4,086,315
1,230,000
932
4
33,000
2,714,124
117,500
300,000
3,164,624
316,462
3,481,086
3,600
2,600
Included in cost of membrane module unit.
-------
OPERATING COST PROJECTIONS
The operating cost projections tabulated in Table 23 are based on
365 operating days per year. The costs are increnental for treating
wastewater at an existing textile plant. The operating costs are items
in three principal categories: (1) labor, (2) electric power, and
(3) membrane replacement. The costs are based on the wages and prices
typical for the Southeast in the fall of 1975. The operating cost pro-
jections in Table 23 do not include the value of recycleable water,
chemicals, or heat (energy). The recycle potential for textile waste-
water renovated by hyperfiltration is estimated separately in Table 24.
The estimates of labor requirements by the four membrane manufacturers
were different. However, the same labor cost is used in the projection
for each membrane system for consistency in comparison. Even though the
pilot plant experience supports the existence of scma variation in labor
requirements, this variation should not be a major consideration in the
comparisons among the four membrane systems.
The membrane life, i.e., the replaceirEnt interval, for the polyamide
fiber membrane and both configurations of the cellulose acetate is taken
as three years. The replacement costs are depreciated linearly over this
time period. The dynamic Zr-PAA membrane replacement interval is taken
to be one year. Of course, determination of membrane life for textile
wastewater treatment is beyond the scope of this pilot plant program. The
maximum evaluation period in the pilot plant study was about 1000 hours.
The experiences of the manufacturers in other applications were the basis
for the selection of the replacement period for the polyamide and cellulose
acetate membrane systems. For the prototype dynamic Zr-PAA membrane system,
the membrane replacement is a minor item. Thus, the accuracy of the re-
placement interval is not significant in the total operating cost project-
ions. Data with textile wastewater do support the estimated one-year
replacement period, however.
The cost projections do not include amortization of capital. Because
of effects of legislation on capital investment for environmental protection
and the fluctuations in the prime interest rate, inclusion of the amortization
75
-------
Tab* 23. OPERATE COST HOJBCnWB SUWKK FOE HYPERFIL^IO, TREMMENT OF LA FRANCE
($/day)
CASE NUMBER
PRETREMMENT UNIT
Filter Aid (@6.6<=Ag)
Chemicals (detergent & acid)
LABOR
Operating (6 man-yrs)
Maintenance (0.5 man-yrs)
Supervision
MAINTENANCE MATERIAL
ELECTRIC POWER (@ 1.5
-------
would add no significant information to the capital cost projections
already presented.
The operating costs for pretreatavent are not a major item.for any
membrane system. The labor, electric power, and irembrane replacement
costs are about equal for the polyamide membrane system. The membrane
replacement costs become progressively more important for the spiral-
wound and tubular cellulose acetate, being the major factor for the
tubular configuration. The major operating cost for dynamic 2r-PM
membranes is the electric power costs. In-situ membrane replacement is
a particularly small cost for the dynamic membranes.
The daily operating cost ranges fron 12.1<:/m3 (45.7
-------
Table 24. NET OPERATING COST PROJECTIONS SUMMARY INCLUDING POTENTIAL RECYCLE CREDITS
-4
CO
CASE NUMBER
RECYCLE POTENTIAL, i3)
2. Salt (@ 4.4<=Ag)
3. Energy Ǥ 1.9C/107 J)
TOTAL RECYCLE CREDITS
UNIT OPERATING COSTS*1
NET OPERATING COSTS, «/m3
NET OPERATING COSTS, <=Agal
1
10.6
1.5
3.4
15.5
12.1
(3.4)b
(12.9)b
2
10.6
1.5
2.8
14.9
13.6
(1.3)b
(4.9)b
3
10.6
1.5
2.8
14.9
25.5
10.6
40.1
4
10.6
1.5
6.2
18.3
18.7
0.4"
1.5
Fran Table 23
Indicates net savings
-------
The net operating costs, Table 24, includes credit for recycle.
A small net savings is projected for the polyamide membrane and the
spiral cellulose acetate membrane systems.
COST PROJECTIONS FOR A COMBINED MEMBRANE SYSTEM
Because of the relatively low capital and operating costs of both
the polyamide and cellulose acetate (spiral) mambrane systems and the
high teitperature capability of the dynamic Zr-PAA membrane system, a
hyperfiltration treatment facility combining two types of membranes has
advantages over any single membrane system.
The dye procedure employed at La France, Table 8, involves the dilution
of the 210 F (99 C) spent scouring and dyeing baths. The dilution is
accomplished with clean, cold rinse water introduced to the dyeing machine.
This procedure results in a slow quenching of the cloth to 165 F (74 C).
Approximately 25% of the water used in dyeing cycle is exhausted to the'
drain at an average temperature of 165 F (71 C). The final rinsing of
the cloth results in a mixed effluent of about 90 F (32 C).
A dynamic Zr-PAA membrane unit can process the relatively hot portion
(25%) of the wastewater and effect energy recovery since with procedural
modifications the 165 F (71 C) water could be directly recycled in many
dyeing operations. Either spiral or hollow-fiber membranes can process
the remaining portion (75%) of the wastewater without requiring a cooling
tower. The following approximations of capital and operating costs
illustrate the cost advantages of such a combined system. A detailed
economic analysis of a combined system was not carried out, however.
Because of the increased membrane flux with temperature, each dynamic
Zr-PAA membrane module has a product- flow rate of 2.06 dmVmin at 71 C.
Therefore, to process 25% of the 7570 mVday wastewater to 82.1% product
recovery requires 524 modules. This is 14% the size of the membrane unit
used in the cost projections summarized in Table 22. As a first approxi-
mation then, the capital costs of this smaller unit is 14% of $3,481,086
or $487,352.
79
-------
The capital cost of the polyanti.de, or spiral cellulose acetate,
portion of the combined unit would be simply 75% of the value given in
Table 22 with the exception that the entire cost of the cooling tower
my be eliminated since the mixed effluent temperature is 32 C. The
capital cost for the unit to process the relatively cool rinse water is
then $1,151,576 for a polyamide membrane unit, or $1,197,611 for a
spiral cellulose acetate membrane unit.
The approximate total capital cost for a combined membrane treatment
is $1,650,000. A comparison with Table 22 indicates this is less than
the capital cost of any single membrane system.
The operating costs for the combined membrane system are also
approximated from the details developed for the individual membrane
systems. The operating costs, excluding labor, are proportional to
system size. That is, the operating cost for the dynamic Zr-PAA manbranes
is 14% of $1162.88 (Table 23), or $162.80. The operating cost of the
polyamide membrane unit is 75% of $661.72 (Table 23), or $496.29. The
labor costs are not reduced, but are taken to be the same for the combined
system as for any other membrane unit, i.e., $252.56. The approximate
operating costs for the combined system is the sum of $162.80, $496.29,
and $252.56, or $911.65. The unit operating cost is 12<=/m3 (45.6C/1000
gallons) of wastewater processed. Comparison of this result with Table 23
shows that the operating cost of the combined system is less than for
any single membrane system.
The credit for recycled water and salt is the same for all membrane
systems (Table 24), 10.6
-------
that a combined system to take advantage of the relatively low costs
of sore roeirfcranes and the energy conservation potential, by direct re-
cycle of hot water, of other nembranes, should be considered for each
application characterized by the utilization of hot dye baths and
relatively cooler, 'higher volunes of rinse water. Further, procedural
alterations to permit direct recycle of dye baths renovated at full
process tenperature couM possibly yield even further energy con-
servation.
81
-------
REFERENCES
1. Kraus, K. A., A. J. Shor, and J. S. Johnson, Jr. Desalination.
2_:243. 1967.
2. Larson, T. J. Desalination. 7^:187. 1970.
3. Brandon, C. A., J. S. Johnson, Jr., R. E. Minturn, and J. J. Porter.
Journal of Textile Chemists and Colorists. _5{7) :134. 1973.
4. Environmental Protection Agency, Demonstration Project #8800929;
Thomas N. Sargent, Project Officer, Southeast Water Laboratory,
Athens, Georgia.
5. Anonymous. Chemical Engineering. 7£(27):53. 1971.
6. Coit, R. L. Proceedings of Third International Symposium on Fresh
Water fran the Sea. 2;351. WTol
7. Johnson, J. S., Jr. "Polyelectrolytes in Aqueous Solutions." Reverse
Osmosis Membrane Research. 379-403. 1972.
8. Fremont, H. A., D. C. Tate, and R. L. Goldsmith. "Color Removal frcm
Kraft Mill Effluents by Ultrafiltration." Final Report, Project
#3800261, Environmental Protection Agency. 1973.
82
-------
SECTION X
APPENDIX A
83
-------
APPENDIX A
WATER SAMPLING SCHEDULE, PROCEDURE, AND CHEMICAL ANALYSES
SAMPLING SCHEDULE
During this project, the detailed chemical analyses of a number of
samples were required for the following reasons: (1) to characterize
the La France composite wastewater, (2) to characterize the product
water and concentrate employed in direct reuse dyeing operations, and
(3) to evaluate the performance of the pilot plant hyperfiltration units.
In order to achieve these goals, a sampling schedule and chemical analysis
routine was established and maintained by pilot plant operators. This
Appendix describes the sampling schedule, sampling procedures, and the
chemical tests performed on the collected water samples.
In order to characterize the composite wastewater frcm the La France
plant, several 0.1 dm3 samples of raw wastewater were collected during
work hours and the samples were mixed at the end of the week to yield a
composite sample of wastewater.
The sample described as composite product water and composite con-
centrate were drawn from the 5.6 m3 storage tanks at the end of each
collection period. The composite raw waste sample which was used as
feed for the pilot plant was prepared by collecting a sample of raw waste
from each 2.3 m3 raw feed batch to be processed and mixed at the end of
the collection period. A sample of tap water was analyzed for comparison
with the composite product water for each reuse dyeing.
COLLECTION AND STORAGE OF SAMPLES
To insure that representative samples were obtained, the following
guidelines were established for sample storage during the project. Samples
were analyzed within a two week period after collection and stored before
analyses at a temperature of less than 5 C. No additives or preservatives
were added to any of the samples because they often affect the results of
many of the analyses.
84
-------
ANALYTICAL PROCEDURES
The chemical analyses were performed by Texidyne, Inc. Those
chemical parameters subject to rapid change after sample collection
-------
Total Organic Carbon (TQC)
TOG is evaluated by difference. Total carbon is first determined
by passing a sample aliquot into a 950 C furnace and conversion of all
carbon present to carbon dioxide. Inorganic carbon is found by passing
a second aliquot into a 150 C oven where only the inorganic carbon is
converted to carbon dioxide. The carbon dioxide from both channels is
determined by an infrared detection system. Standard solutions of
sodium carbonate and biocarbonate , and potassium acid phthalate are used
to calibrate the carbon channels. Total organic carbon is then evaluated
as the difference between total carbon and inorganic carbon.
Determination of pH is made with a potentiometric pH meter calibrated
with buffers of known pH value.
Alkalinity
Alkalinity is determined by titrating a known volume for the sample
to a pH of 4.5 with a standard acid solution. The results are expressed
as mg/A calcium carbonate.
Hardness
Hardness is determined by cotplexing the calcium and magnesium ions
present in an aliquot of the sample with EDTA solution to a titrimetric
end point indicated by Eriochrcme Black T. The results are expressed as
mg/£ calcium carbonate.
Total Solids
Total solids is taken as the weight of solid residue after an aliquot
of the homogeneous sample is dried at 105 C for 24 hours. The results
are expressed as mg/£ solids.
86
-------
Volatile Solids
Volatile solids is taken to be the weight of solid material which
volatilizes when the residue of the total solids determination is heat-
ed to 650 c for 15 minutes. The result is expressed as rag/A.
Dissolved Solids
Dissolved solids is the weight of solid matter remaining after a
sampOfi is filtered at roan temperature through Whatman #42 filter paper
or equivalent, and a measured aliquot of the filtrate is dried at 105 C
for 24 hours. The result is expressed as mg/£.
Color
The determination of color is made by comparing the absorbance of
the sample at 410 m with those of standard platinum-cobalt color solutions,
also at 410 rm. The results are expressed as platinum-cobalt color units.
Turbidity
Turbidity is measured using a nephelcmeter type turbidimster. Light
scattered by the sample is incident upon a photo-tube, which is connected
to a meter movement. Calibration is made against standards of known
turbidity. The results are expressed in Formazin Turbidity Units (PTU).
Conductivity
A conductance bridge and cell of known cell constant calibrated
against standard potassium chloride solutions is used for determining
conductivity. The result is expressed in micranhos per centimeter
(nmho/cm).
Metals
Metals are determined by atonic absorption spectrophotoitetry with
comparison made to standards formulated for the various metals according
87
-------
to guidelines presented in Perkin-Elmer Analytical Msthods for Atomic
Absorption Spectrophotometry.
All metals except mercury were determined with an air acetylene
flame. Msrcury was determined by the flameless technique. It should
be noted that, because of this special technique, mercury can be
reported in the yg/£ range, while other metals are limited to the
mg/£ range.
Rajection
The observed rejection is defined by the relationship
R = i - concentration of product
obs concentration of feed
88
-------
SECTION XT
APPENDIX B
89
-------
APPENDIX B
PRODUCTION SCALE FEUSE DYEINGS
The production scale reuse dyeings demonstrated the technical
feasibility of direct recycle of both the product water and concentrate
from hyperfiltration of cotposite wastewater. After collection of
sufficient water for reuse, 1.9 - 5.7 m3 of concentrate and 11.4 - 17 m3
of product water, mixed samples were used in the laboratory, at the
plant, to develop production scale dye formulations for use in a two-
piece beck, Machine No. 19.
The product water was found to be reuseable with no adjustment of
standard dye formulations. Even the most critical shade, a light covert
shade on a 54% nylon - 46% viscose blend fabric, was repeatedly achieved
with no difficulties. The concentrate required special formulations to
produce standard comtercial shades.
For each test dyeing, standard production procedures were followed
in the dyehouse. The standard dyeing procedure, given in Table 8 in the
text, involves scouring and rinsing steps in addition to the dyeing and
shade adjustment.
Two types of plant dyeings were carried out: (1) separate dyeings
with the product water and with the concentrate, and (2) one dyeing
combining both the concentrate and the product water. When used separately,
the product water was used in all of the six scouring, rinsing, and dyeing
steps in the standard procedure. When used in combination, the product
water was used in all steps except the dyeing; the dyebath was the concen-
trate. When used separately, the normal process water was used for scour-
ing and rinsing with the concentrate as the dyebath.
In this Appendix are given the details of the water analyses of the
product water and concentrate, the standard and special dye formulations,
and the evaluation of each test cycle. Cycle #11, #13, and #15 are omit-
ted because no dyeings were done during these periods which were devoted
solely to equipment performance evaluations.
90
-------
CYCLE #1
The analyses of the average feed to the DuPont module, the product
water, and the concentrate are tabulated in Table B-l.
Table B-l. WATER ANALYSES FOR CYCLE #1 (March 22, 1973)
COD, mg/£
BOD, mg/Jl
TOC, mg/Jl
pH
Alkalinity, mg/Jl
Hardness, mg/fc
Total Solids, mg/Jl
Volatile Solids, mg/Jl
Dissolved Solids, mg/&
Color (Pt-Co units)
Turbidity, F.T.U.
Conductivity (wriho/cm)
Metals
Calcium, mg/Jl
Zinc, mg/Jl
Magnesium, mg/H
Chranium, mg/Jl
Copper, mg/A
Iron, mg/Jl
Mercury, ygA '",
Manganese, mg/£
Sodium, mg/Jl
Feeda
Water
Analyses
160
45
36
6.5
50
40
1030
140
980
500
44.0
1150
1.0
4.8
0.51
-
0.04
0.3
-
-
Product
Water
Analyses
25
10
3
6,1
10
30
100
30
100
30
2.4
180
0.5
<0.04
<0.01
-
0.04
0.3
-
-
-
Concentrate
Water
Analyses
425
70
87
6.7
110
90
2360
200
2330
850
39.0
2200
3.0
9.7
1.18
-
0.18
3.0
-
-
-
a This is the analyses of a composite sample taken from the feeds that
were used during Cycle #1 for the DuPont nodule,
91
-------
Product Water
The first plant dyeing using product water was conducted on a 54%
nylon - 46% viscose blended fabric using a dye formulation containing
7 different dyes, Table B-2. Laboratory dyeings were conducted to
establish the suitability of the product water with the shade chosen
before the plant dyeing was performed. This particular fabric and dye
formulation were chosen because, in the opinion of the plant dyer and
chemist, this was one of the most difficult dye systems in use in the
plant.
Table B-2. CYCLE #1 PRODUCT WATER REUSE DYEING3
Chemical
Acid Dye
Acid Dye
Acid Dye
Acid Dye
Direct Dye
Direct Dye
Direct Dye
Salt
Dye Name
Nylon Fast Yellow FLW
Ciba Brown 2GL
Ciba Yellow 2BRL
Irgalan Black RBL
Lumicrease Grey 3LBN
Lumicrease Orange 3LG
Lumicrease Bordeau SLR
Weight Used
Based On
% Fabric Wt.
0.018
0.039
0.017
0.016
0.027
0.030
0.006
10.
43 kg of fabric in a dyebath of 1.5 m3 at pH = 6 - 7.
The color obtained from the above dye formulation was a gold shade
(light covert). While the causes for the production difficulties with
this shade are not documented, it is known to give more problems than most
of the dye/fabric systems used. The problems have been attributed to the
quality of the plant water, improper cleaning of the dyeing equipment,
improper temperature control during the dyeing operation, and inaccurate
92
-------
measure of dyes and chemicals used for dyeing. It was assumed that this
dye/fabric system constituted a critical test for the reuse of product
water in the plant.
A light shade of gold was produced with the product water. The
dyeing operation proceeded normally with no visible problems occurring.
The product water was used in all steps in the dyeing operation. This
particular fabric passed a 100-hour Weather-CHMeter Test, a severe test
of light fastness.
Concentrate Water
Before a dye/fabric system was selected to be used with the con-
centrate water, the plant laboratory conducted trial dyeings using the
concentrate water as the dyebath. This was done to select a system to
best use the dyes present in the concentrate. This could be successful
only when the current production shades were similar to the shade of the
concentrate water. At other times a production shade had to be chosen
that obscured the dyes present in the concentrate water.
The concentrate produced by the hyperfiltration module for the
first cycle was a grey-green color. Laboratory dyeings gave grey-green
shades on standard test fabrics. Since no green dye shades were
scheduled for the plant production this particular week, a tan shade
(Color No. 133) on a 100% cotton velour fabric was chosen for use with
the concentrate for this test, Table B-3.
The tan shade was produced on the velour fabric with no difficulty
being encountered during the dyeing operation. The results of the light
fastness test and crock test were the sama as that obtained with normal
dyeing procedures. The fabric was graded as first quality and sold.
93
-------
Table B-3. CYCLE #1 CONCENTRATE WATER REUSE DYEING3
Chemical
Direct Dye
Direct Dye
Direct Dye
Direct Dye
Direct Dye
Salt
Dye Name
Bellchem Yellow EPC
Calco Rsd 6ELL
Diphenyl F Blue 4GL
Sol Brown GEL
Sup F Blue 8GUN
Dye Used Based
Test Dyeing
0.349
0.044
0.019
20.
on % Fabric Wt
Normal Dyeing
0.341
0.025
0.043
0.029
a
21.8 kg of fabric in a dyebath of 0.87 m3 at pH = 7.
The fabric was finished with a Scotchgard,
94
-------
CYCLE #2
The analyses of the average feed to the DuPont module, the product
water, and the concentrate are tabulated in Table B-4.
Table B-4. WATER ANALYSES FOR CYCLE-#2 (April 24, 1973)
COD, mg/Jl
BOD, mg/Jl
TOC, mg/Jl
pH
Alkalinity, mg/Jl
Hardness, mg/Jl
Total Solids, mg/Jl
Volatile Solids, mg/Jl
Dissolved Solids, mg/Jl
Color (Pt-Co units)
Turbidity, F.T.U.
Conductivity (piriho/cm)
Metals
Calcium, mg/£
Zinc, mg/A
Magnesium, mg/£
Chromium, rag/A
Copper, mg/£
Iron, mg/Jl
Mercury, vg/l
Manganese, mg/Jl
Sodium, mg/Jl
Feeda
Water
Analyses
315
35
65
6.0
55
40
1155
175
'I 1095
810
19,0
i) 1900
Product
Water
Analyses
20
5
5
6.0
15
15
270
N.D.
270
20
0,5
580
Concentrate
Water
Analyses
815
135
200
6.5
135
120
5570
450
5540
1250
31.0
1030
3.30
0.25
0.75
0,1
<0.13
N.D.
10.4
2.0
7.2
iS^ a^yses of a cotiposite sample taken fron the feeds that
were used during Cycle #2 for the DuPont nodule.
95
-------
Product Water
The product water was used to dye a yellow shade (Color No. 114)
on a ribbed, 100% cotton velour fabric, Table B-5. The dyeing operation
was conducted by normal plant procedures with no problems being en-
countered.
Table B-5. CYCLE #2 PRODUCT WATER REUSE DYEING3
Chemical
Direct Dye
Direct Dye
Salt
Dye Name
Bellchem Yellow ETC
Intralite F Yellow 2GLL
Weight Used
Based On
% Fabric Wt.
0.046
0.600
20.
a 64.8 kg of fabric in a dyebath of 1.5 m3 at pH = 6 - 7.
Concentrate Water
The concentrate water was used to dye a medium dark blue-green shade
(Color No. 676 ) on a 100% cotton velour fabric, Table B-6.
The concentrate in the laboratory produced a dull grey shade on a
test fabric. Since the plant had no production color to match this dull
grey color, a darker color had to be used so that the dullness would not
affect the color of the final dyed fabric. This is a limitation that
arises when the concentrate contains many different dyes and chemicals.
The dyeing operation proceeded normally with no apparent problems.
The desired blue^green shade was obtained on the 100% cotton velour
fabric. The crocking test was good and comparable to results obtained
with fabric dyed in the normal manner. The fabric in that test did show
significant facing after 40-hours exposure in the Fade-O-Meter. This was
not considered unusual for this particular shade and therefore was not
96
-------
attributed to the use of the concentrate water, The fabric was graded
as first quality and sold.
Table B-6. CYCLE #2 CONCENTRATE WATER REUSE DYEING*1
a
44.1 kg of fabric in a dyebath of 1.5 m3 at pH = 7.
Chemical Dye Name Dye Used Based on % Fabric Wt.
*vye iMcune Test Dyeing Normal DyelnT
Direct Dye Solo Green 5BL i.03 0.900
Direct Dye Intralite F Yellow 2GLL 0.018 0*032
Salt
15.
97
-------
CYCLE #3
The analyses of the average feed to the DuPont module, the product
water, and the concentrate are tabulated in Table B-7.
Table B-7. WATER ANALYSES FOR CYCLE #3 (May 21, 1974)
COD, mgA
BOD, mgA
TOC, mgA
pH
Alkalinity, mgA
Hardness, mgA
Total Solids, mgA
Volatile Solids, mgA
Dissolved Solids, mgA
Color (Pt-Co units)
Turbidity, F.T.U.
Conductivity (ymho/on)
Metals
Calcium, mgA
Zinc, mgA
Magnesium, mgA
Chromium, mgA
Copper, mgA
Iron, mgA
Mercury , vg/a
Manganese, mgA
Sodium, mgA
Feeda
Water
Analyses
220
40
70
6.75
45
40
855
140
825
680
1.7
1300
-
-
2.06
0.2
1.08
-
"
Product
Water
Analyses
20
5
5
6.4
15
20
130
20
130
13
1.3
200
-
-
-
<0.4
0.56
"
Concentrate
Water
Analyses
455
60
no
7.0
110
80
2545
280
2480
1500
1.6
3800
-
-
-
0.84
0.3
1.24
This is the analyses of a composite sample taken from the feeds that
were used during Cycle #3 for the DuPont module.
98
-------
Product Water and Concentrate
To establish the conpatibilit* of the product water and concentrate
xt was decided to use them together in a plant production dyeing. The
product water was used for all water needs in the dyeing procedure ex-
cept the actual dyeing operation, *hen the concentrate was used as the
dyebath.
*
A light blue shade (Color No. 662) was dyed on a 65% cotton - 35%
rayon velour, Table B-8. The shade was selected to achieve good utili-
zation of the dyes in the concentrate. A 71% reduction of dyes, compared
to that required in standard formulation, was achieved.
The light fastness and crocking fastness of the dyed fabric was
normal. Even though the shade was not in the production schedule, it is
a catalog shade and demonstrates that savings can be achieved frcm dye
recycling.
This cloth was graded first quality but sold as second because the
small yardage of fabric dyed was not part of the scheduled production.
Table B-8. CYCLE *3 COMBINED PRODUCT WATER
AND CONCENTRATE REUSE'DYEING^
Chemical Dye Name Pye Used Based On % Fabric wfa.
- ^yename Test Dyeing Normal Dyeing'
Direct Dye Sup F Blue 8GUJ
Direct Dye Bellchem Yellcw ETC
Direct Dye Direct Fast Red 8BIN
Direct Dye Pyrazol F Blue
Salt
n,
37 kg of fabric in a dyebath of 1.5 m3 at PH = 7.
99
-------
CYCLE #4
The analyses of the average feed to the DuPont module, the product
water, and the concentrate are tabulated in Table B-9.
Table B-9. WATER ANALYSES FOR CYCLE 14 (June 12, 1973)
COD, mgA
BOD, mgA
TOC, mgA
pH
Alkalinity, mgA
Hardness, mgA
Total Solids, mgA
Volatile Solids, mgA
Dissolved Solids, mgA
Color (Pt-Co units)
Turbidity, F.T.U.
Conductivity (pmho/cm)
Metals
Calcium, mgA
Zinc, mgA
Magnesiun, mgA
Chrcmium, mgA
Copper, mgA
Iron, mgA
Mercury, V9A ?
Manganese, mgA
Sodium, rag/ 1
3 rnui i a *-Vi*a analvrRAfi of £
Feed3
Water
Analyses
245
49
70
6.8
55
30
970
95
945
470
40
1600
2.3
-
2.9
-
240
» coiDOsite sartrx
Product
Water
Analyses
15
4
5
6.5
15
5
280
40
280
6
0.8
540
0.24
-
0.28
~
"
94
Le taken from the
Concentrate
Water
Analyses
580
102
165
7.2
160
90
3020
310
2985
1000
40
4800
6.5
10.2
M>
" *
^*
980
feeds that
ill^O t^o »»*»^* **+u*^~j ~ ^ a.
were used during Cycle #4 for the DuPont module.
100
-------
Product-Water and Concentrate
The procedure of combining the product water and concentrate in
a single reuse test dyeing (as in Cycle 13) was repeated. The con-
centrate yielded a grey shade on the laboratory test fabric. A rose
shade (Color No. 405) was selected to get maximm use of the dyes in
the concentrate. A 100% cotton velour fabric was dyed in the full
scale reuse test, Table B-10.
The light fastness of the fabric dyed with the concentrate was
equal to the standard material. The plant scale dyeing proceeded
normally. The fabric was sold as first quality.
Table B-10. CTCIE #4 COMBINED PRODUCT WATER
AND OaONTRATE REUSE DYEING^
Chemical
Direct Dye
Direct Dye
Direct Dye
Direct Dye
Salt
CL *^ n f» t * »
Dye Name
Direct Fast Red 8BIW
Bellchem Yellow ETC
Superlite Blue 8GEN
Calco Red G BLL
Dye Used Based
0.094
0.092
0.047
10.
On % Fabric Wt.
Noxiiial Dyeina
0,167
0.047
0.088
10.
101
-------
CYCLE #5
The analyses of the average feed to the DuPont module, the product
water, and the concentrate are tabulated in Table B-ll.
Table B-ll. WATER ANALYSES FOR CYCLE #5 (July 7, 1973)
COD, mgA
BOD, mgA
TOC, mgA
pH
Alkalinity, nigA
Hardness, mgA
Total Solids, mgA
Volatile Solids, mgA
Dissolved Solids, mgA
Color (Pt-Co units)
Turbidity/ F.T.U.
Conductivity (ymho/on)
Metals
Calcium, mgA
Zinc, mgA
Magnesium, mgA
Chrcmium, mgA
Copper, mgA
Iron, mgA
Mercury, ygA
Manganese, mgA
Sodium, mgA
Feeda
Water
Analyses
230
45
50
6.4
45
25
990
135
930
510
45,0
2000
1.10
4.40
3.10
0.1
-
300
Product
Water
Analyses
15
0.3
5
6.5
25
5
440
40
440
30
3.4
1000
0.10
0.08
0.22
0.1
*""
"
"
~
160
Concentrate
Water
Analyses
690
95
220
7.2
190
135
4425
405
4230
1200
30.0
9500
9.0
8.50 ,
13.8
0.1
1400
« ^ i »_
This is
were used during Cycle
(^i^mwi^BM"*"^^^^^^"-
. a composite sample taken from the feeds that
#5 for the DuPont module.
102
-------
Product Water and Concentrate
The procedure of combining the product water and concentrate in
a single reuse test dyeing (as in Cycle #3) was repeated. The con-
centrate yielded a grey shade on the laboratory test fabric. A violet
shade (helio) was selected to get maximum use of the dyes in the con-
centrate. A 100% cotton velour fabric was dyed in the full scale reuse
test, Table B-12.
The light fastness of the fabric dyed with the concentrate was
equal to the standard material. The plant scale dyeing proceeded normally.
The fabric was sold as first quality.
Table B-12. CYCLE #5 COMBINED PRODUCT WATER
AND CONCENTRATE REUSE DYEING3
Chemical
Direct Dye
Direct Dye
Salt
Dye Name
Direct Fast Red 8BLN
Pyrazol Fast Violet 4BL
Dye Used Based
Test Dyeing
0.01
0.12
25.
On % Fabric Wt.
Normal Dyeing
0.01
0.12
25.
37 kg of fabric in a dyebath of 1.5 m3 at pH = 7.
103
-------
CYCLE #6
The analyses of the average feed to the DuPont module, the product
water, and the concentrate are tabulated in Table B-13.
Table B-13. WATER ANALYSES FOR CYCLE #6 (September 20, 1973)
COD, Itq/SL
BOD, rcq/SL
Feeda
Water
Analyses
170
15
Product
Water
Analyses
25
1
Concentrate
Water
Analyses
435
10
TOC,
pH
Alkalinity, mg/fc
Hardness, mg/Jl
Total Solids, mg/£
Volatile Solids, mg/£
Dissolved Solids, mg/Jl
Color (Pt-Co units)
Turbidity, F.T.U.
Conductivity (ymho/on)
Metals
Calcium, icg/a
Zinc, mg/£
Magnesium, mg/£
ChratuLum, mg/Jl
Copper, mgA
Iron, mg/£
Mercury,
Manganese,
Sodium, mg/£
6.6
45
45
780
130
755
595
55
850
1.0
4.0
4.0
0.08
250
7.1
15
10
285
60
285
60
6.3
520
0.5
0.7
0.9
0.08
90
7.4
140
130
3425
315
3435
1250
80
6200
6.0
9.0
17
2.0
1120
a This is the analyses of a corposite sample taken frcm the -feeds that
were used during Cycle #6 for the DuPont nodule.
104
-------
Product Water
The product water was used with the same dye/fabric system as
Cycle #1, i.e. a goJd shade (light covert) on a 54%'nylon - 46% viscose
bland. During Cycle #6, 90% of the wastewater was recovered as product
water. Therefore, the product water contained more impurities than in
the previous reuse tests. Thus it was decided to again check separately
its suitability for plant use, see Table B-2. In Cycle #6, 45.4 kg of
fabric were dyed in a 1.5 m3 dyebath at a pH of 6 - 7.
The light fastness and wash fastness of the dyed fabric was good
and comparable to that obtained with normal plant dyeings. No adverse
results were observed fron the use of the product water in the plant
dyeing.
Concentrate Water
The concentrate water was used with the same tan shade (Color No 133)
on 100% cotton velour fabric, dyed in Cycle #1. This shade was repeated
so that a comparison could be made of the results obtained with the dyeing
in Cycle #1, Table B-14. This corparison was desired because at 90%
water recovery, the concentrate contains more dyes and dinpurities.
The dyeing operation proceeded normally with no apparent problems.
The same shade was produced on the cotton velour fabric as was used for
the concentrate in Cycle #1. The light fastness of the dyed fabric was
comparable to that obtained with regular production dyeings. The material
was graded as first quality and sold.
105
-------
Table B-14. CYCLE #6 CONCENTRATE WATER REUSE DYEINGa
Dye Used Based OH % Fabric Wt.
Chemical
Direct Dye
Direct Dye
Direct Dye
Direct Dye
Direct Dye
Salt
Dye Name
Bellchem Yellow EPC
Calco Red 6BLL
Diphenyl F Blue 4GL
Sol Brown GRL
Sup F Blue 86IN
Test Dyeing
0.280
0.015
0.010
20.
Normal Dyeing
0.341
0.025
0.043
0.029
20.
89.4 kg of fabric in a dyebath of 1,5 m3 at pH = 7.
106
-------
CYCLE #7
The analyses of the average feed to the ORNL module, and the
concentrate are tabulated in Table B-15.
Table B-15. WATER ANALYSES FOR CYCLE #7 (November 6, 1973)
GCD, mg/Jl
BCD, mg/A
TOC, mg/£
pH
Alkalinity, mg/A
Hardness, rcg/i
Total Solids, mg/£
Volatile Solids, itg/H
Dissolved Solids, mg/£
Color (Pt-Co units)
Turbidity, F.T.U.
Conductivity (varho/cm)
Metals
Calcium, mg/Jl
Zinc, mg/&
Magnesium, mg/Jl
Chromium, mg/£
Copper, mg/A
Iron, mg/£
Mercury, yg/s, t
Manganese, mg/Jl
Sodium, mg/A
Feed3
Water
Analyses
150
10
25
8.1
75
15
860
120
820
510
35
1400
0.53
1.70
1.87
_
4.0
_
250
Concentrate
Water
Analyses
190
15
_
8.0
155
50
1580
165
1480
1300
8.5
1700
0.96
2.4
4.5
^
18
_
470
, , -.- °f a oonpcsite sample taken from the feeds that
were used during Cycle #7 for the OHNL nodule.
107
-------
Concentrate Water
For Cycle #7, the concentrate water was used for the dyebath formu-
lation and regular process water was used for all other phases of the
dyeing operation. The product water had been used interchangeably with
process water in previous dyeings and its suitability for plant use had
been demonstrated. In Cycle #7, the primary interest was in the use of
the concentrate to further demonstrate dye recovery.
The concentrate water produced a dyeing with a light pink shade on
cotton test fabric. Because of this, a rose shade (Color No. 405) was
chosen for the plant dyeing of a 100% cotton velour fabric, Table B-16.
The plant dyeing proceeded normally with no problems being observed with
the use of the concentrate water.
The light fastness was the same as that normally obtained with
fabric dyed this shade. The fabric was sold as first quality.
Table B-16. CYCLE # 7 CONCENTRATE WATER REUSE DYEING3
Chemical
Direct Dye
Direct Dye
Direct Dye
Dye Name
Sup F Blue 8GLN
Bellchem Yellow ETC
Direct Fast Red 8BLN
Dye Used Based
Test Dyeing
0.060
0.125
20.
On % Fabric Wt.
Normal Dyeing
0.146
0.028
15.
69.4 kg of fabric in a dyebath of 1.5 m3 at pH = 7,
108
-------
CYCLE #8
The analyses of the average feed to the OKNL module, and the
concentrate are tabulated in Table B-17.
Table B-17. WATER ANALYSES FOR CYCLE #8 (November 26, 1973)
COD, rcg/i
BOD, Kg/a
TOC,
355
970
450
2.8
Feedc
Water
Analyses^
220
35
P 6.8
Alkalinity, mg/Ji 35
Hardness, mg/A 20
Total Solids, mg/SL
Volatile Solids, mg/SL
Dissolved Solids, mg/a
Color (Pt-Co units)
Turbidity, F.T.U.
Conductivity (yirho/cm)
Metals
Calcium, rng/A
Zinc, mgA
Magnesium, mg/fc
dhromium, mg/£
Copper,
Iron, mg/A
Mercury
Manganese
Sodium, mg/A 325
a This is the analyses of a composite saitple taken from
were used during Cycle #8 for the ORNL module.
1.90
2.63
Concentrate
Water
Analyses
415
45
7.5
115
55
2510
275
2450
1680
15.0
1850
8.1
3.14
9.6
40.0
780
^M^Wi
the feeds that
109
-------
Concentrate Water
As in Cycle #7, the concentrate water was used with the regular
process water and the product water was not used in the plant.
The concentrate water produced a dyeing with a light blue-grey
shade on cotton test fabric. Because of this a blue-green shade (Color
No. 616) was chosen for the plant dyeing on a 100% cotton velour,
Table B-18.
The light fastness of the dyed fabric was the same as that obtained
with fabric dyed by normal procedures. The dyed fabric did show some
slight side-to-center shading. This was probably the result of a twist
in the fabric rope during dyeing. This problem was not associated with
the concentrate water. The fabric was sold as first quality.
Table B-18. CYCLE #8 CONCENTRATE WATER REUSE DYEING3
Chemical
Direct Dye
Direct Dye
Direct Dye
Direct Dye
Salt
Dye Name
Sup F Blue SOU
Sup Yellow ETC
Direct Fast Red 8BLN
Pyrazol Blue 2GLN
Dye Used Based
Test Dyeing
0.420
0.065
25.
On % Fabric Wt.
Normal Dyeing
0.099
0.016
0.517
15.
45.4 kg of fabric in a dyebath of 1.5 m3 at pH = 7.
110
-------
CYCLE #9
The analyses of the average feed to the ORNL meddle, the product
water, and the concentrate are tabulated in Table B-19.
Table B-19. WATER ANALYSES FOR CYCLE #9 (January 23, 1974)
OCD, mgA
BOD, mgA
TOG, mgA
pH
Alkalinity, mgA
Hardness, mgA
Total Solids, mgA
Volatile Solids, mgA
Dissolved Solids, mgA
Color (Pt-Co units)
Turbidity, F.T.U.
Conductivity (yitiho/an)
Metals
Calcium, mgA
Zinc, rogA
Magnesium, mgA
Chromium, mgA
Copper, ngA
Iron, mgA
Marcury, ygA
Manganese, mgA
Sodium, mgA
Iteeda
Water
Analyses
230
35
-
6.6
45
25
1085
170
1050
180
20
1050
0.88
5.20
2.76
-
2.38
-
-
350
Product
Water
Analyses
30
2.7
7,2
40
4
630
95
630
30
1.5
715
0.17
0.06
0.58
-
-
0.63
-
-
270
Concentrate
Water
Analyses
265
30
-
7.1
105
95
1515
285
1445
470
30
1200
6.40
7.04
5.76
-
-
18.1
-
-
505
a This is the analyses of a oorrposite sanple taken from the feeds that
were used during Cycle #9 for the OINL nodule.
Ill
-------
Product Water
The product water was used to dye the same shade (light covert) and
fabric (54% nylon - 46% viscose) used with the product water in Cycle #1.
This was done so a comparison could be made between tiie product water
from the DuPont hollow fiber polyamide membrane module and the product
water from a dynamic membrane module. This light shade provided a
critical test for the reuse of the product water, see Table B-2, In
Cycle #9, 48 kg of fabric were dyed in a dyebath of 1.5 m3 at pH of 6 - 7.
The desired shade was obtained with no problems being encountered.
The dyed fabric passed all of the tests for light fastness and crocking.
Concentrate Water
The concentrate water was used to dye a light tan shade (oyster) on
100% cotton velour, Table B-20.No dyes were added to the concentrate water
and the shade produced was due solely to the dyes in the concentrate.
The dyeing operation proceeded normally with no apparent problems.
The fabric exhibited satisfactory light fastness and was sold commercially.
Table B-20. CYCLE #9 CONCENTRATE WATER REUSE DYEING
Chemical
Salt
Dye Name
Dye Used Based On % Fabric Wt.
Test DyeingNormal Dyeing
10. -b
21.8 kg of fabric in a dyebath of 1.5 m3 at pH = 7.
No dyes were added to the dyebath.
112
-------
CYCLE #10
The analyses of the average feed to the Westinghouse module, the
product water, and the concentrate are tabulated in Table B-21.
Table B-21. WATER ANALYSES FOR CYCLE #10 (January 22, 1974)
COD, icq/l
BCD. ma/A
Feed3
Water
Analyses
150
15
Product
Water
Analyses
200
1.3
Concentrate
Water
Analyses
385
25
TOC, mgA
P»
Alkalinity, mgA
Hardness, ragA
Total Solids, mgA
Volatile Solids, mgA
Dissolved Solids, mgA
Color (Pt-Co units)
Turbidity, F.T.U.
Conductivity (ymho/cm)
totals
Calcium, mgA
Zinc, mgA
Magnesium, mgA
Qiromiun, mgA
Copper, mgA
Iron, rag A
Mercury, pg/A '
Manganese,
Sodium, mg/Jl
6.6
25
30
655
120
645
490
25
950
1.43
6.00
5.84
2.38
190
6.2
3
6
215
75
205
60
6
340
0.88
0.82
0.78
1.13
55
7.1
90
105
1765
240
1740
960
125
2250
2.57
16.0
8.00
3.00
600
a This is the analyses of a cottposite sanple taken from the feeds that
were used during Cycle #10 for the Westinghouse module.
113
-------
Product Water
The product water was used to dye the same shade (light covert) and
fabric (54% nylon - 46% viscose) used with the product water in Cycle #1.
This was done so a comparison could be made between the product water
from the DuPont hollow fiber polyamide membrane module and product water
from the Westinghouse cellulose acetate membrane module. This shade
provided a critical test for the reuse of the product water, see Table B-2,
In Cycle #10, 46.2 kg of fabric were dyed in a dyebath of 1.5 m3 at pH
of 6 - 7.
The desired shade was obtained with no problems being encountered.
The dyed fabric passed all of the tests for light fastness and crocking.
Concentrate Water
The concentrate water was used to dye a burnt-orange shade (Color
No. 214), on 100% cotton velour fabric, Table B-22. The concentrate
water gave a light grey shade by itself so little dye was present in the
concentrate.
The dyeing operation proceeded normally with no apparent problems.
A burnt-orange shade was produced on a cotton velour fabric. The light
fastness of the dyed fabric was comparable to that obtained with regular
production dyeings and the fabric was sold as first quality.
Table B-22. CYCLE #10 CONCEOTMTE WATER REUSE DYEING3
Chemical
Direct Dye
Direct Dye
Direct Dye
Salt
Dye Used Based On % Fabric Wt.
Dye Name
Fastusol Orange LTG
Supra Light Fast Blue 8GLN
Fast Red 8 BLN
Test Dyeing
1.500
0.020
0.065
20.
Normal Dyeincj
1.500
0.040
0.080
20.
44 kg of fabric in a dyebath of 1.5 m3 at pH = 7.
114
-------
CYCLE #12
The analyses of the average feed to the DuPont module, the product
water, and the concentrate are tabulated in Table B-23.
Table B-23. WATER ANALYSES FOR CYCLE #12 (March 4, 1974)
OCD, mg/£
BOD, lug/Si
TOC, mg/£
pH
Alkalinity, mg/£
Hardness, mg/&
Total Solids, icg/Si
Volatile Solids, mg/t
Dissolved Solids, ng/i
Color (Pb-Co units)
Turbidity, F.T.U.
Conductivity (vimho/on)
Metals
Calcium, mg/£
Zinc, mg/Jl
Magnesium, mg/Ji
Chronvium, mg/£
Copper, mg/Jl
Iron,
Mercury,
Manganese, mg/i
Sodium, mg/A
a This is the analyses of a coiposite sartple taken from the
were used during Cycle #12 for the DuPont nodule.
Feed3
Water
Analyses
no
15
6.5
30
50
1160
155
1150
320
5.5
1400
7.20
3.60
9.00
0.07
395
Product
Water
Analyses
10
2
6.4
10
3
230
65
230
20
2.0
400
1.00
0.50
0.42
0.04
75
Concentrate
Water
Analyses
365
15
6.8
95
245
4320
245
4320
920
3400
3400
34.0
7.20
27.0
0.45
1470
VH^
feeds that
115
-------
Product Water and Concentrate
The product water and concentrate were used together in this dye
cycle. The concentrate gave a light tan shade on a cotton velour test
fabric. After checking several production shades for which the con-
centrate could be used, a burnt-orange shade (Color No. 212) was select-
ed, Table B-24.
A burnt-orange shade was produced on a 100% cotton velour fabric.
No problems were encountered during the dyeing operation and the fabric
was graded as first quality.
Table B-24. CYCLE #12 COMBINED PRODUCT WATER
AND CONCENTRATE REUSE DYEING21
Chemical
Direct Dye
Direct Dye
Direct Dye
Direct Dye
Salt
Dye Name
Diaz-Orange 5JA
LumHDR-Brown 3LB
Dir. F-Fted 8BIN
Sol Brown GRUST
Dye Used Based
Test Dyeing
1.350
0.020
0.080
25.
On % Fabric Wt.
Normal Dyeing
1.780
-
0.090
0.070
15.
23.6 kg of fabric in a dyebath of 1.5 m3 at pH 6 - 7,
116
-------
CYCLE #14
The analyses of the average feed to the Gulf module, the product
water, and the concentrate are tabulated in Table B-25.
Table B-25. WATER ANALYSES FOR CYCLE #14 (May 7, 1974)
COD, mg/Jl
BOD, rag/A
TOC, mgA
pH
Alkalinity, mg/ji
Hardness, mg/A
Total Solids, rrg/A
Volatile Solids, mg/Ji
Dissolved Solids, mg/£
Color (Pt-Co units)
Turbidity, F.T.U.
Conductivity (yrriho/cm)
Metals
Calcium, mg/&
Zinc, mg/fc
Magnesium, mg/fc
Chromium, mg/A
Copper, mg/Jt
Iron, icg/i
Mercury, yg/A1
Manganese, mg/£
Sodium, mg/Jl
Feeda
Water
Analyses
160
10
35
6.2
50
75
670
145
655
280
30
580
1,80
0.96
3.10
0.30
0,12
0.14
-
0.14
225
Product
Water
Analyses
25
1
5
5.9
8
0.5
45
15
50
40
2.5
80
0.08
0.04
0.02.
0.10
0.04
0.14
-
0.03
15
Concentrate
Water
Analyses
430
20
230
6.7
160
190
3025
275
3025
1100
35
2000
7.50
3.04
15.0
0.60
2.50
0.14
_
0.60
1090
i. . v
were used during Cycle #14 for the Gulf module.
fran the feeds that
117
-------
Product Water and Concentrate
The product water and concentrate were used together in this dye
cycle, also. The concentrate gave a grey-green shade on a cotton test
fabric. After checking several production shades for which the con-
centrate could be used, it was decided to select a gold shade (Color
No. 175) which had not previously been used in the pilot study, Table
B-26.
The gold shade was produced on a 100% cotton velour fabric. No
problems were encountered during the dyeing operation and the fabric
was graded as first quality.
Table B-26. CYCLE #14 COMBINED PRODUCT Wk
AND CONCENTRATE REUSE DYEING3
Chemical
Direct Dye
Direct Dye
Direct Dye
Direct Dye
Salt
Dye Name
Diaz-Orange 5JA
Intralite Green RT.T.
Intralite Red 6BLL
Bellchem Yellow EFL
Dye Used Based
Test Dyeing
0.900
0.040
' 0.020
0.030
20.
On % Fabric Wt.
Normal Dyeing
0.950
0.061
0.022
-
15.
71.2 kg of fabric in a dyebath of 1.5 ra3 at pH = 6 - 7.
118
-------
CYCLE #16
The analyses of the average feed to the Selas module, the product
water, and the concentrate are tabulated in Table B-27.
Table B-27. WATER ANALYSES FOR CYCLE #16 (July 9, 1974)
COD, rag/A
BOD, mg/Jl
TOC, mg/Jl
PH
Alkalinity, mg/Ji
Hardness, rag/A
Total Solids, mg/A
Volatile Solids,
Dissolved Solids, nvg/£
Color (Pt-Co units)
Turbidity, F.T.U.
Conductivity (prriho/cm)
Metals
Calcium, itg/s,
Zinc, mg/SL
Magnesium, mg/£
Chromium, mg/Ji
Copper, mg/A
Iron, rag/A
Mercury, yg/jj,
Manganese, mg/Ji
Sodium, rog/A
Feed3
Water
Analyses^
160
30
7,1
40
55
805
780
295
6.3
1250
5.20
0.94
4.40
Product
Water
Analyses
15
-
5
9.2
20
20
195
190
30
0.45
450
0.20
0.02
0.26
Concentrate
Water
Analyses
255
55
100
9.0
250
130
3110
3055
190
18
4200
15.5
1.80
12.0
119
-------
Concentrate Used with Regular Plant Water
The product water was not used in a plant scale dyeing because of
the results of several earlier recycle dyeings which established that
water of this quality could be used interchangeably with process water.
The concentrate gave a grey-green shade on a cotton velour test fabric.
After checking several production shades for which the concentrate
could be used, a green shade (special) was selected, Table B-28.
A medium green shade was produced on a 100% cotton velour fabric.
No problems were encountered during the dyeing operation and the fabric
was graded was first quality.
Table B-28. CYCLE #16 CONCENTRATE WATER REUSE DYEING3
Chemical
Direct Dye
Direct Dye
Direct Dye
Salt
Dye Name
Int. Green KT.T.
Sup Yellow ETC
Dir. Red 5BIW
Dye Used Based
Test Dyeing
0.050
0.170
0.015
20.
On % Fabric Wt.
Normal Dyeing
_b
-
-
16.3 kg of fabric in a dyebath of 1.5 m3 .at pH = 6 - 7.
No dyes were added to the dyebath.
120
-------
SECTION XII
APPENDIX C
121
-------
Table 0-1. PEHTORttNOS OF HYPEFFnaj»nCN tfXVIES IN TOE IA FRNEE PHOT PIJWT
Rejection and Absoluts Values of OOD, BCD, TOC, and
to
NJ
Sanple Operating
nunber tirae(hrs)
4
7
12
16
22
23
24
25
26
27
28
29
31
33
35
36
37
39
42
44
46
48
50
52
53
Cycle No.
7
16
13
27
37
49
55
61
70
76
84
88
92
Cycle No.
94
102
106
108
119
131
145
150
155
161
170
179
CCD
S
P
C R%
S
BCD
P
C
R%
1 - DuPont Penneator I7753N
730 20 1370 97.3 -
400 20 590 95.0 -
DuPont Penneator I7725N
160 10 350 93.8 -
200
195
130
295
300
205
190
170
215
175
20
20
10
10
10
15
15
35
60
15
430 90.0
405 89.7
300 92.3
505 96.6
415 96.7
280 92.7
270 92.1
380 79.4
315 72.1
250 91.4
_
35
_
20
-
-
50
_
<1
_
2
-
-
-
20
_
_
_
125
40
-
-
-
130
-
_
>97.1
_
90.0
-
-
-
60.0
-
_
S
140
45
30
35
25
30
75
70
65
45
35
45
45
TOC
P
5
5
2
3
15
3
4
2
7
3
7
-
4
C
245
135
100
75
70
55
160
115
90
80
75
65
80
S*
96.4
88.9
93.3
91.4
40.0
90.0
94.7
90.7
89.2
93.3
80.0
-
91.1
S
7.0
7.8
6.1
6.4
6.8
6.3
6.8
6.6
6.8
6.8
6.6
6.6
6.8
PH
P
8.0
8.0
5.6
5.7
6.1
5.8
6.3
6.2
6.4
6.2
6.2
6.4
6.4
C
7.2
7.2
6.4
6.8
6.9
6.6
7.2
6.9
6.8
7.0
7.3
6.8
6.5
2 - DuPont Penneator I7725N
700
415
540
940
330
375
445
650
795
1040
970
1155
20
1
1
30
15
30
70
85
100
195
180
195
870 97.1
615 99.8
790 99.8
1235 96.8
445 95.5
525 92.0
620 84.3
995 86.9
1260 87.4
1590 81.3
1515 81.4
1795 83.1
90
-
-
65
-
-
220
-
15
-
-
-
-
_
15
-
-
60
-
-
125
-
-
-
-
-
105
-
-
295
-
-
83.3
-
-
-
-
-
76.9
-
-
72.7
-
-
130
110
130
260
70
100
115
190
335
310
380
315
10
10
5
15
10
5
15
20
25
50
10
60
185
190
235
445
125
140
175
385
605
655
495
590
92.3
90.9
96.2
94.2
85.7
95.0
87.0
89.5
92.5
83.9
97.4
81.0
6.7
6.3
6.2
6.4
6.3
6.4
6.4
6.6
6.8
6.7
6.9
7.1
5.9
6.0
6.1
6.0
6.0
6.2
5.9
6.2
5.9
6.3
6.2
6.3
6.9
6.8
6.7
6.4
6.5
6.6
6.5
7.0
7.3
7.0
7.1
7.2
-------
Table C-l. (continued)
hJ
CJ
Saople
nunber
55
60
61
65
frm
67
f A
69
71
73
"TC
75
77
79
81
82
84
86
88
89
91
94
96
99
101
104
108
116
117
118
120
Operating
time(hrs)
Cycle No,
188
209
217
231
284
326
400
423
427
Cycle No.
24
28
37
41
49
62
148
170
218
Cycle No.
236
251
275
284
305
337
Cycle No.
437
439
442
445
COD
S P C R% S
. 3 - DuPont Pexmeator I7725N
500 55 760 89.0 -
645 45 850 93.0 -
235 35 330 85.1 -
245 . 40 455 83.7 25
45 15 85 66.7 -
45 15 60 66.7 -
280 40 380 85.7 55
130 30 165 76.9 -
85 35 165 58.8 -
4 - DuPont Pezneator I7753N
590 30 850 94.9 -
440 25 615 94.3 -
390 35 485 91.0 -
350 30 495 91.4 -
290 20 495 93.1 -
280 55 380 80.4 36
440 25 560 94.3 75
450 15 575 96.7 -
150 10 190 93.3 -
5 - DuPont Pezneator I7753N
540 5 735 99.1 -
690 40 790 94.2 -
440 40 495 90.9 -
260 30 290 88.5 55
840 35 1025 95.8 -
420 20 460 95.2 -
6 - DuPont Pezneator I7725N
150 35 160 76.7 -
175 35 275 80.0 -
205 40 250 80.5 -
425 50 500 88.2 -
BOD
P
5
-
5
-
-
-
-
-
-
7
15
-
-
-
-
-
10
-
-
-
-
-
-
C
45
-
60
-
-
-
-
-
60
85
-
-
-
-
-
60
-
-
-
-
-
-
R%
80.0
90.9
-
-
-
-
-
80.6
80.0
-
-
-
-
-
81.8
-
-
-
-
-
-
S
140
200
40
65
10
10
40
30
25
150
115
95
105
90
100
115
115
-
145
220
125
55
265
100
20
30
30
25
TOC
P
15
10
5
10
2
3
10
5
10
5
5
5
5
6
20
7
5
_
10
10
5
10
10
5
15
6
15
15
C
235
245
55
140
25
15
70
45
45
245
165
125
160
140
145
155
165
245
255
145
65
475
115
25
35
40
45
R%
89.3
95.0
87.5
84.6
80.0
70.0
75.0
83.3
60.0
96.7
95.7
94.7
95.2
93.3
80.0
93.9
95.7
93.1
95.5
96.0
81.8
96.2
95.0
25.0
80.0
50.0
40.0
S
7.7
7.0
7.0
7.1
7.2
7.2
7.0
6.9
7.0
6.9
6.7
6.6
7.0
6.6
7.0
7.1
6.9
7.1
7.2
7.0
7.1
7.2
7.6
7.4
6.8
6.8
7.0
6.8
f*
P
6.7
6.5
6.2
6.6
6.6
6.5
6.7
6.4
6.6
5.9
6.2
6.2
6.1
6.0
6.3
6.8
6.4
6.2
6.7
6.5
6.2
6.2
6.4
6.6
6.4
6.6
6.5
6.8
C
8.1
7.2
7.1
7.5
7.2
7.5
7.2
7.0
7.1
7.0
6.8
6.7
7.0
6.9
7.1
7.4
7.1
7.2
7.4
7.4
7.2
7.2
7.7
7.4
6.8
7.0
7.1
6.8
-------
Table C-l. (continued)
Saaple
nunfcer
121
124
126
128
129
139
141
141
142
143
144
149
150
151
153
154
155
158
159
160
162
163
164
167
169
172
179
183
188
194
Operating
time(hrs)
452
463
471
503
506
Cycle No.
~
-
Cycle No.
-
-
~
Cycle No.
-
-
-
-
-
-
-
-
-
-
ODD
S f C
780 130 975
90 15 125
150 25 195
105 15 110
130 25 155
7 - OBNL Module
150 15
225 5
135 15
160 15
150 15
8 - OBNL Module
225 40
290 45
195 30
265 35 -
320 50 -
335 50
9 - ORE, Module
110 5
190 10
370 20
445 10
1105 20
1260 30
1630 55
270 65
690 65
210 35
505 40
835 70
970 55
BOD
R%
83.3
83.3
83.3
85.7
80.8
90.0
97.8
88.9
90.6
90.0
82.2
84.5
84.6
86.8
84.4
85.1
95.5
94.7
94.6
97.8
98.2
97.6
96.6
75.9
90.6
83.3
92.1
91.6
94.3
S
15
-
-
^
_
7
-
25
-
_
_
-
-
-
-
-
-
P
5
_
-
:
_
2
-
7
-
_
_
_
-
-
_
-
-
-
-
-
_
-
-
C R%
15 66.7
_ _
_ _
71.4
- _
72.0
_ _
_ _
_ _
- -
- _
. _
- -
- -
- -
- -
- -
-
-
S
90
15
20
7
10
25
30
15
30
20
55
30
35
50
65
65
35
65
95
85
105
295
315
80
185
65
145
200
190
TOC pH
P
15
2
7
2
4
10
1
4
10
5
15
8
6
10
7
4
-
10
4
8
15
4
15
10
4
15
15
15
C
120
40
25
8
15
_
_
-
^
_
-
_
_
_
_
_
_
_
_
_
_
M
_
-
R%
83.3
86.7
65.0
71.4
60.0
60.0
96.7
73.3
66.7
75.0
72.7
73.3
82 v 9
80.0
89.2
93.8
-
-
89.5
95.3
92.4
94.9
98.7
81.3
94.6
93.8
89.7
92.5
92.1
S
7.0
7.2
7.3
7.9
7.4
8.7
7.6
6.8
8.9
7.9
8.1
6.6
7.1
6.2
6.6
6.6
7.4
7.8
8.4
7.8
8.2
10.0
7.4
10.2
8.4
7.0
7.4
7.6
7.8
P
6.7
6.6
7.0
7.2
6.9
8.7
7.0
8.6
9.8
9.6
8.2
6.4
6.8
7.0
6.9
6.9
6.9
8.6
9.0
8.4
8.8
10.3
7.6
10.1
8.8
7.6
7.8
7.2
8.1
C
7.0
7.1
7.4
7.7
7.4
^
-
_
-
^
_
_
_
^
_
^
_
--
-------
Table 0-1. (continued)
to
en
Saple
renter
165
168
173
174
176
177
178
180
182
192
195
203
204
208
209
210
212
218
220
223
225
230
232
235
236
205
207
Operating
tineOirs)
Cycle No.
23
95
143
387
435
502
530
545
Cycle No.
556
701
744
Cycle No.
1
10
22
26
31
48
63
80
105
128
160
165
176
178
Cycle No.
COO
S P
C R%
10 - Meetinghouse Module
265 75
520 10
625 10
825 20
1230 25
1630 25
890 30
1140 90
260 71.7
98.1
98.4
97.6
97.8
98.5
96.6
92.1
11 - Westinghcuse Module
130 6
685 15
145 35
12 - DuPcnt
470 15
75 10
635 10
425 20
290 10
190 2
360 25
145 35
120 10
145 210
320 20
155 30
55 20
160 30
95.4
97.8
75.9
BOD
S P C R%
14-291
- _
- - _ _
- - - -
- _ _ _
_ _ _
_
- _ _ _
_ _ _
#4-291
- _ _ _
- _
- - -
TOC
S
50
no
55
150
210
135
155
240
45
140
115
P
8
7
10
5
6
10
8
20
6
5
10
C
60
_
.
w
_
_
.»
_
_
R%
84.0
93.6
81.8
96.7
97.1
92.6
94.8
91.7
86.7
96.4
91.3
Pezseator 1400600
1135 96.8
110 86.7
1215 98.4
910 95.3
430 96.6
270 98.9
760 93.1
210 75.9
225 91.7
255 -
575 93.8
230 80.6
70 63.6
225 81.3
_ _
- _ _ _
- _ _ _
_ _
_ _ _ _
_ _ _ _
_ _ _
_ - - _
_ _ _ _
_ _ _ _
- _ -
_ _ _
_ _ _
80
15
105
105
45
20
15
30
30
25
75
50
15
20
9
10
10
10
-
-
2
1
6
7
2
n
i
5
150
70
215
170
65
30
15
35
60
40
75
50
15
45
88.8
33,3
90.5
90.5
-
-
86.7
96.7
80.0
72.0
97.3
78.0
93.3
75.0
S
7.0
7.5
7.3
6.9
7.0
7.2
7.0
7.0
6.8
7.6
6.9
6.6
6.3
6.8
6.5
6.5
6.5
6.4
6.3
8.0
6.6
6.4
6.4
6.7
6.3
PH
P
6.2
6.0
6.0
5.9
6.1
6.1
6.2
6.4
5.6
6.7
6.4
6.2
6.0
8.6
6.2
5.6
5.3
6.1
5.9
9.6
6.0
6.2
6.0
6.2
6.2
13 - OWC Module
- -
-
_ _ _ _
_ _ _ _
_
_
_
_
_
-
_
_
_
_
C
7.1
^
_
_
_
^
_
6.5
6.4
7.2
6.7
6.6
6.6
6.4
6.4
7.4
6.4
6.5
6.5
6.7
6.4
Cycle No. 14 - Gulf Nodule
-------
Table C-l. (continued)
Sanple
ranter
239
246
250
252
254
256
257
258
259
260
262
263
264
272
273
274
277
278
281
282
287
289
290
Operating
time(hrs)
93
165
193
252
272
316
434
583
631
633
684
708
779
Cycle No.
-
-
-
-
-
-
-
-
-
*"
GOD
S
255
280
180
315
795
655
720
660
630
345
390
440
380
P
9
20
15
85
15
35
25
30
35
15
20
15
20
16 - Selas
240
-
-
360
-
380
390
160
210
250
20
20
20
30
10
-
15
10
15
C
330
350
290
400
1175
675
795
790
740
480
480
570
460
Module
-
-
-
-
-
~
R%
96.5
92.9
91.7
73.0
98.1
94.7
96.5
95.5
94.4
95.7
94.9
96.6
94.7
91.7
-
97.4
-
90.6
95.2
94.0
S
m
_
20
175
205
_
_
_
_
_
_
15
20
-
-
_
_
~
BCD
P
_
2
60
6
..
_
_
_
_
3
2
-
-
-
-
_
-
_
_
~
C
mf
_
25
205
260
_
_
_
_
_
_
20
-
-
-
-
-
-
-
~
R%
_
90.0
65.7
97.1
_
_
_
_
_
_
80.0
90.0
_
-
_
-
~
S
60
65
30
155
160
no
170
145
90
80
no
135
55
80
145
145
30
55
70
TOC
P
7
3
2
-
4
8
8
15
8
5
10
6
7
7
7
7
-
10
6
9
5
2
5
C
90
75
45
-
225
165
165
170
220
105
95
120
195
-
-
-
-
-
-
R%
88.3
95.4
93.3
97.4
95.0
92.7
91.2
94.5
94.4
87.5
94.5
94.8
87.3
_
-
95.9
93.8
83.3
96.4
92.9
S
6.7
5.8
6.8
6.4
6.7
6.6
6.8
7.1
7.2
6.9
6.4
6.7
7.0
7.4
7.6
8.2
7.5
7.1
8.2
8.3
I*
P
5.7
6.6
6.2
5.2
6.9
5.9
6.2
6.4
5.9
6.2
6.1
5.9
6.1
6.6
6.3
6.3
9.3
9.4
7.3
7.7
8.9
9.2
C
6.8
6.0
6.8
6.4
7.0
6.6
6.9
7.0
7.2
6.8
6.6
6.6
7.0
_
_
_
~
a S - supply to module; P = permeate (or product); C = concentrate (or residue); R = 1 - (P/S) - rejection
An results are in mg/i except for pH (unitless).
-------
Table C-2. PERPOBCWCE OF HYPERFmTRATICN MODULES IN THE IA FRANCE PHOT PLANT
Rejection and Absolute Values of Alkalinity, Hardness, Total Solids, and Volatile Solids3
H
to
Sanple
nuober
4
7
12
16
22
*>>
23
24
25
26
27
28
29
31
33
35
36
37
39
42
44
46
48
50
52
53
Operating
timefrrs)
Cycle No.
7
16
13
27
37
49
55
61
70
76
84
88
92
C^cle No.
94
102
106
108
119
131
145
150
155
161
170
179
S
Alkalinity
P
C
R%
Hardness
S
1 - DuPont Pezmeator I7753N
110 10 250 90.0 40
DuPont Penneator I7725N
30 5 100 83.3 35
30
45
60
90
130
125
120
70
no
105
10
10
10
10
10
10
10
10
20
15
2 - DuPont
115
150
105
105
no
90
130
245
385
195
230
320
20
10
15
15
15
25
15
20
30
25
25
30
85
120
135
190
195
160
185
170
160
140
66.7
77.8
83.3
88.9
92.3
92.0
91.7
85.7
81.8
85.7
40
45
40
35
45
45
45
50
60
60
P
30
20
25
15
15
15
10
10
15
10
10
10
C
140
70
100
110
95
70
60
60
65
90
90
90
R%
25.0
42.9
37.5
66.7
62.5
57.1
77.8
77.8
66.7
80.0
83.3
83.3
Total Solids
S
5390
1250
840
1490
830
850
1095
1560
1550
1490
1315
2105
1660
P
230
40
60
135
80
75
85
85
95
100
170
180
155
C R%
8930 95.7
3600 96.8
2460 92.9
4070 90.0
2360 90.4
2150 91.2
2420 92.2
2380 94.6
2090 93.9
2370 93.3
3445 87.1
3270 91.4
2570 90.7
Volatile Solids
S
420
Mt
155
195
^
155
195
175
Penneator I7725N
150
195
150
115
155
no
190
380
615
285
355
480
82.6
93.3
85.7
85.7
86.4
72.2
88.5
91.8
92.2
87.2
89.1
90.6
70
50
45
no
60
120
40
70
120
90
110
165
15
15
15
10
15
15
15
10
15
10
10
15
80
65
80
135
70
165
50
110
185
no
165
235
78.6
70.0
66.7
90.9
75.0
87.5
62.5
85.7
87.5
88.9
90.9
90.9
10650
3350
2380
4175
1420
3020
910
1730
2765
1575
1940
2660
1200
240
130
390
85
380
80
135
220
150
185
235
15920 88.7
4965 92.8
3720 94.5
5505 90.7
2095 94.0
4245 90.7
1370 91.2
2760 92.2
4610 92.0
2365 90.5
2945 90.5
4135 91.2
275
215
190
545
200
225
215
355
485
355
380
P
60
^^
40
35
^
^
65
70
75
95
85
60
95
55
85
25
40
55
65
70
C R%
550 85.7
_ _
320 74.2
325 82.1
_
_ _
295 58.1
260 64 1
w w^*A
240 57.1
3935 88.7
330 60.5
365 68.4
645 82.6
280 72.5
325 62.2
295 88.4
525 88.7
925 88,7
510 81.7
575 81.6
-------
Table C-2. (continued)
Senple
ranter
Operating
tiroe(hrs)
Alkalinity
Hardness
Total Solids
Vblatile Solids
S
R%
R%
R%
R%
00
Cycle No. 3 - DuPont PentEator I7725N
55 188 120 10 185 91.7 50 10
60 209 110 25 140 77.3 295 20
61 217 50 10 65 80.0 85 10
65 231 no 30 200 72.7 30 5
67 284 60 25 110 58.3 10 2
69 326 65 25 110 61.5 5 1
71 400 70 25 110 64.3 40 10
73 423 70 30 105 57.1 25 5
75 427 65 30 100 53.8 20 5
Cycle No. 4 - DuPont Perneator I7753N
77 24 80 15 130 81.3 55 5
79 28 85 15 no 82.4 75 5
,_, 81 37 75 25 105 66.7 55 5
to 82 41 100 15 135 85.0 70 5
84 49 65 15 105 76.9 50 5
86 62 105 20 145 81.0 40 4
88 148 120 25 150 79.2 65 5
89 170 85 15 105 82.4 50 5
91 218 80 15 100 81.3 55 5
Cycle No. 5 - DuPont Penneator #7753N
94 236 115 20 145 82.6 80 5
96 251 170 30 210 82.4 150 5
99 275 155 25 175 83.9 115 5
101 284 210 35 245 82.3 75 5
104 305 205 35 250 82.9 225 5
108 337 160 25 180 84.4 90 5
Cycle No. 6 - DuPont Perneator I7725N
116 437 65 25 80 61.5 90 15
n7 439 55 20 70 63.6 15 5
US 442 70 25 85 64.3 20 5
120 445 40 10 50 75.0 30 5
60
390
100
40
20
12
50
80.0
93.2
88.2
83.3
80.0
80.0
75.0
2020
3385
1185
8000
530
520
1160
150
315
115
240
160
160
310
3105
4410
1525
1610
885
880
1825
92.6
90.7
90.3
97.0
69.8
69.2
73.3
295
380
245
100
US
150
175
55
75
60
85
105
55
70
400
505
285
365
220
245
215
81.4
80.3
75.5
15.0
8.7
63.3
60.0
45 80.0 1040 385 1630 63.0 US 60 160 47.8
30 75.0 965 '475 1600 50.8 100 60 145 40.0
105 90.9 2525 270 4400 89.3 400 no 495 72.5
105 93.3 2535 325 3575 87.2 265 80 360 69.8
75 90.9 1730 410 2295 76.3 290 85 350 70.7
100 92.9 2990 290 4290 90.3 205 30 270 85.4
90 90.0 1440 145 2415 89.9 170 85 260 50.0
80 87.5 1200 200 1760 83.3 155 50 230 67.7
65 92.3 2130 285 2855 86.6 265 90 355 66.0
70 90.0 2020 225 2650 88.9 290 90 365 69.0
65 90.9 1925 155 2370 91.9 165 25 210 84.8
110 93.8 3835 560 5055 85.4 370 50 490 86.5
190 96.7 5245 650 6305 87.6 360 85 470 76.4
135 95.7 3945 360 4050 90.9 275 50 295 81.8
90 93.3 1980 355 2315 82.1 320 80 320 75.0
270 97.8 5400 690 6675 87.2 715 60 620 91.6
105 94.4 3785 455 4420 88.0 345 55 315 84.1
125
20
35
30
83.3
66.7
75.0
83.3
1150
790
1020
680
330
175
260
165
1500
1030
1360
865
71.3
77.8
74.5
75.7
200
135
145
230
65
80
45
65
220
135
175
270
67.5
40.7
69.0
71.7
-------
Table C-2. (continued)
K
Ssnple
nuifcer
121
124
126
128
129
139
141
142
143
144
149
150
151
153
154
155
158
159
160
162
163
164
167
169
172
179
183
188
194
Operating
time(hrs)
452
463
471
503
506
Cycle Mo.
-
_
_
_
Cycle No.
.
_
_
»
_
Cycle No.
_
_
M
_
_
w
_
_
_
-
Alkalinity
S
90
40
105
50
75
P
25
10
40
10
20
C
120
50
130
60
90
B%
72.2
75.0
61.9
80.0
73.3
S
85
15
45
30
55
Hardness
P
10
5
5
5
10
C
110
20
60
40
70
R%
88.2
66.7
88.9
83.3
81.8
Total Solids
S P
1810 385
520 125
1555 350
515 105
920 225
C
2330
650
2010
630
1100
R%
78.7
76.0
77.5
79.6
75.5
Volatile
S
425
185
140
85
120
P
150
55
45
25
40
Solids
C R%
535 64.7
170 70.3
160 67.9
95 70.6
140 66.7
7 - QRNL Module
55
120
75
95
140
20
25
30
40
40
-
_
_
63.6
79.2
60.0
57.9
71.4
15
80
10
20
15
2
1
0.5
0.5
0.5
-
_
-
86.7
98.8
95.0
97.5
96.7
890 190
1730 235
1170 220
525 70
705 80
-
-
-
-
-
78.7
86.4
81.2
86.7
88.7
-
-
105
140
155
-
50
40
30
52.4
71.4
80.6
8 - ORNL Module
150
45
35
25
60
75
60
20
15
15
25
30
_
_
_
_
_
-
60.0
55.6
57.1
40.0
58.3
60.0
55
30
40
120
60
90
10
3
3
10
4
2
-
-
_
-
-
81.8
90.0
92.5
91.7
93.3
97.8
2480 980
470 3.60
695 175
1190 360
1365 445
1460 490
-
-
-
-
-
-
60.5
66.0
74.8
69.7
67.4
66.4
180
355
135
265
175
160
55
45
50
50
45
50
69.4
87.3
63.0
81.1
74.3
68.8
9 - OFNL Module
45
60
85
90
105
235
180
175
175
55
105
115
35
15
25
35
30
35
95
50
65
55
25
30
20
20
_
_
_
_
_
_
_
_
_
_
-
66.7
58.3
58.8
66.7
66.7
59.6
72.2
62.9
68.6
54.5
71.4
82.6
42.9
30
25
45
40
80
30
75
20
65
100
100
170
190
<0.5
1
2
1
2
0.5
2
0.4
3
3
4
6
9
-
_
-
_
_
_
_
_
_
_
-
98.3
96.0
95.6
97.5
97.5
98.3
97.3
98.0
98.4
97.0
96.0
96.5
95.3
865 155
1290 240
2400 440
1905 295
3230 500
3905 560
4670 780
1360 210
3555 800
1385 445
2545 725
3515 930
3950 1080
-
-
-
-
-
-
-
-
-
-
-
-
-
82.1
81.4
81.7
84.5
84.5
85.7
83.3
84.6
77.5
67.9
71.5
73.5
72.7
220
150
300
315
650
765
845
215
410
155
375
555
685
70
25
85
95
80
90
60
85
110
45
110
105
80
68.2
83.3
71.7
69.8
87.7
88.2
92.9
60.5
73.2
71.0
70.7
81.1
88.3
-------
Table C-2. (continued)
Sanple
nunber
165
168
173
174
176
177
178
180
182
192
i ne
195
203
204
208
209
). A
210
212
*\1 ft
218
220
223
225
230
232
235
236
205
207
Operating
timeQirs)
cycle No.
23
95
143
387
435
502
530
545
Cycle No.
556
701
744
Cycle No.
1
10
22
26
31
48
63
80
105
128
160
165
176
178
Cycle No.
-
-
Altelinitv
p
t:
10 - Westinghovae
75 5 75
150 5
180 10
170 6
245 7
325 9
190 10
225 20
11 - Westinghouse
40 2
380 10
135 8
12 - DuPont
150 15
30 7
95 10
100 6
80 7
30 2
25 6
45 5
80 15
60 7
100 20
60 7
30 8
45 10
Module
93.3
96.7
94.4
96.5
97.1
97.2
94.7
92.2
Module
95.0
97.4
Hardness
S
P
C
R%
Total Solids
S P
C R%
Volatile
S
P
Solids
C R%
14-291
60
150
190
124
605
370
150
200
14-291
30
100
94.1 225
Permeator 1400600
265
50
180
170
120
55
30
75
140
80
125
85
40
45
90.0
76.7
89.5
94.0
91.3
93.3
76.0
88.9
81.3
88.3
80.0
88.3
73.3
77.8
40
n
35
30
30
40
70
30
70
35
75
150
80
60
0.5
1
2
1
30
2
5
15
2
6
3
1
5
1
0.05
1
1
10
1.5
10
6
2
2
4
6
60
:
150
20
60
65
50
70
30
70
340
40
75
215
120
105
99.2
99.3
98.9
99.2
95.0
99.5
96.7
92.5
93.3
94.0
98.7
97.5
54.5
97.1
99.8
96.7
97.5
85.7
95.0
85.7
82.9
97.3
98.7
95.0
90.0
1380 40
3190 130
3915 155
2265 80
3210 no
4155 170
2365 115
3115 255
505 15
4955 225
4190 220
5475 215
1260 25
4925 90
2715 50
4515 110
1615 35
16035 1040
700 20
865 25
3020 175
1905 100
1735 140
770 85
1085 135
13 - ORNL Module
_ _
-
_
-
«
_
_
_
_
1380 97.1
95.9
96.0
96.5
96.6
95.9
95.1
91.8
97.0
95.5
93.6
11380 96.1
2345 98.0
14755 98.2
5515 98.2
6820 97.6
9255 97.8
19490 93.5
1170 97.1
1505 97.1
5190 94.2
3140 94.8
2570 91.9
1265 89.0
1760 87.6
~ ~
150
370
405
430
660
815
470
590
115
515
370
940
100
840
245
490
55
335
90
170
140
210
205
105
135
10
50
50
25
45
20
35
40
7
30
45
105
15
40
45
1
1
60
15
15
US
35
25
40
45
150 93.3
86.5
87.7
94.2
93.2
97.5
92.6
93.2
93.9
94.2
87.8
2055 88.8
130 85.0
7090 95.2
845 81.6
1175 99.8
170 98.2
540 82.1
180 83.3
245 91.2
240 17.9
365 83.3
275 87.8
165 61.9
180 66.7
Cycle No. 14 - Gulf Module
-------
Table C-2. (continued)
SanixLe Operating
nunber time(hrs)
239
246
250
252
254
256
257
258
259
260
262
263
264
272
273
274
277
278
281
282
287
289
290
a s-
b All
93
165
193
252
272
316
434
583
631
633
684
708
779
Cycle No.
-
-
_
_
-
-
S
110
45
50
60
300
150
225
315
290
195
no
135
150
16 -
35
-
-
45
-
55
80
40
70
90
simply to module; P
results are in
rag/*.
.AUcalinity
P
10
8
5
10
15
15
20
25
25
10
9
20
10
Selas
15
15
15
10
10
30
10
15
20
C
150
55
60
70
365
210
265
370
345
240
135
165
180
Module
-
-
-'
-
-
-
-
-
*
- permeate (or
R% S
90.9 60
82.2 70
90.0 40
83.3 30
95,0 105
90.0 145
91.1 230
92.1 100
91.4 75
94.9 100
91.8 95
85.2 155
93.3 95
57.1 50
_
- -
70
_ _
81.8 65
62.5 200
75.0 55
78.6 100
77.8 130
product); C
Hardness
P
2
9
2
3
1
1
1
0.5
0.5
0.5
0.5
0.5
0.5
15
20
15
-
15
10
15
15
15
20
C
85
70
45
60
310
210
230
280
175
110
135
305
210
-
_
-
_
_
-
-
-
-
R%
96.7
87.1
95.0
90.0
99.0
99.3
99.6
99.5
99.3
99.5
99.5
99.7
99.5
70.0
_
_
_
_
84.6
92.5
72.7
85.0
84.6
= concentrate (or
Total Solids
S P
1240 15
1995 45
1290 25
1210 70
5135 175
5720 195
5495 195
5335 210
4990 185
1465 40
3340 95
4215 115
2175 60
1065 125
210
215
1330 -
120
1705 140
2080 180
805 70
1415 125
2005 195
residue); R
C R%
1685 98.8
2520 97.7
1680 98.1
1520 94.2
6340 96.6
6850 96.6
6645 96.5
6535 96.1
6070 96.3
1855 97.3
4385 97.2
4855 97.3
2665 97.2
88.3
_ _
_ _
_
_ _
91.8
91.3
91.3
91.2
90.3
= 1 - (P/S) =
Volatile Solids
S P
220 1
155 6
95 5
175 40
460 9
654 20
595 75
585 45
430 30
315 25
295 15
480 75
280 30
_
_
_ _
_ _
M
_ _
- -
_ _
** *
~
rejection
C R%
280 99.5
225 96.1
130 94.7
180 77.1
555 98.0
690 96.9
620 87.4
635 92.3
550 93.0
365 92.1
760 94.9
440 84.4
215 89.3
_ _
_ ^
_ _
_
^
_ _
_ . _
_ _
_ _
-------
Table C-3. PERFORMANCE OP HXPERFILTRATICtI MODULES IN THE LA FRANCE PHOT PLANT
Rejection and Absolute Values of Dissolved Solids, Color, Turbidity, and Conductivity*
(mg/t)b
C
ro
Sanple
ntnber
4
7
12
16
22
23
24
25
26
27
28
29
31
33
35
36
37
39
42
44
46
48
50
52
Operating
time(hrs)
Cycle No.
7
16
13
27
37
49
55
61
70
76
84
88
92
Cycle No.
94
102
106
108
119
131
145
150
155
161
170
Dissolved Solids
S P
1 - DuPont
5235 230
DuPont
-
810 80
1085 90
-
_
1265 170
- -
2 - DuPont
C R%
Color
S P
C
R%
Turbidity
S
P
C
R%
Conductivity
S
P
C R%
Perroeator I7753N
8880 95.6
-
1450 5
850 5
2400
990
99.7
99.4
0.7
54
0.1
0.33
0.1
1.7
85.7
99.4
5000
1450
400
65
8000 92.0
2500 95.5
Perraeator I7725N
-
-
2275 90.1
2350 91.7
-
- -
3445 86.6
- -
-
485 5
395 15
250 10
180 15
1300 10
1300 10
900 10
800 10
305 5
400 5
550 10
1390
990
600
650
2300
1900
1150
1200
650
550
700
99.0
96.2
96.0
91.7
99.2
99.2
98.9
98.8
98.4
98.8
98.2
1.7
15
7.0
2.0
2.0
0.61
0.69
0.84
5.8
4.5
3.7
0.21
0.52
0.4
0.35
0.24
0.25
0.25
0.1
0.43
0.36
0.31
0.3
26
2.8
3.1
0.25
0.24
0.35
0.31
2.4
3.0
2.4
87.6
96.5
94.3
82.5
88.0
59.0
63.8
88.1
92.6
92.0
91.6
1100
1650
1000
1100
1350
1750
1800
1750
1900
2900
2250
130
250
140
145
180
175
200
205
300
320
290
Pexmeator I7725N
10650 1200 14090 88.7
- -
- -
- -
- -
910 80
- -
- -
1565 135
-
- -
- -
- -
- -
- - -
1370 91^2
- -
- -
2340 91.4
-
590 30
1000 15
1150 15
1800 20
1350 10
1300 10
650 20
950 30
1000 35
1350 50
790 50
800
1750
1400
1650
1800
1750
950
1400
1450
1910
1140
94.9
98.5
98.7
98.9
99.3
99.2
96.9
96.8
96.5
96.3
93.7
25
31
10
25
45
14.0
6.0
3.0
2.8
3.0
1.9
0.84
0.33
0.22
0.54
0.24
0.46
1.0
0.35
0.3
0.36
0.34
22
30
0.70
23
41
0.61
11.0
1.70
1.9
2.0
1.5
96.6
98.9
97.8
97.8
99.5
96.7
83.3
88.3
89.3
88.0
82.1
25600
6400
4100
7200
2600
6000
1320
2820
4840
2600
3050
2760
610
255
860
175
850
112
245
420
230
260
2600 88.2
2900 84.8
2500 86.0
2000 86.8
2700 86.7
2400 90.0
2300 88.9
2500 88.3
5000 84.2
3750 89.0
2900 87.1
38000 89.2
9500 90.5
6400 93.8
10300 88.1
3750 93.3
7200 85.8
2400 91.5
4330 91.3
7150 91.3
3600 91.2
5000 91.5
-------
Table C-3 (continued)
CO
Saiple
ranter
53
55
60
61
V^
65
67
W *
69
71
73
/ J
75
77
70
77
Dl
ol
ftO
o&
86
88
DO
89
01
yj.
94
Af
96
AA
99
101
* A *
104
108
116
117
Operating
timeQirs)
179
Cycle No.
188
209
217
^~LI
231
*)AA
401
one
*JAV
400
A?"*
4^J
427
cycle No.
24
OQ
£0
*)"T
37
M T
4J.
Irt
49
62
148
"1 *TA
170
*)l a
218
Cycle No.
236
251
275
284
305
337
Cycle No.
437
439
Dissolved Solids
g p j.
t; MS
Color
S P
- 750 55
. 3 - DuPont Fenneator I7725N
^ «
790 210
~
1150 305
1 - DuPont
- -
"" ^
«.
* ^
1180 200
2090 260
l ~
5 - DuPont
-
~
1980 345
~
- -
1565 73.4
^ ^
1790 73.5
780 20
4100 35
25 . 10
545 45
50 10
35 10
625 60
205 40
160 35
Perneatar I7753N
-
~ ~
*~ ^
1730 83.1
2835 87.6
~
710 8
1250 8
520 6
410 6
460 4
440 4
1000 8
1600 8
- 450 8
Permeator I7753N
-
2315 82.6
320 4
1100 4
800 8
2200 6
1600 25
1100 10
C
1130
1000
4400
55
830
90
60
800
325
245
1120
1600
600
590
675
605
1500
2200
550
450
1400
920
250
2000
1210
R%
92.7
97.4
99.1
60.0
91.7
80.0
71.4
90.4
80.5
78.1
98.9
99.4
98.8
98.5
99.1
99.1
99.2
99.5
98.2
98.8
99.6
99.0
97.3
98.4
99.1
Turbidity
§
0.93
0.51
5.3
2.4
45
2.3
0.7
23
2.5
2.0
2.5
1.5
40
16.0
20
4.5
55
210
2.6
2.2
3.8
13.0
16.0
12.0
32.0
P t
0.25 0.71
0.25 0.36
1.2 3.9
0.45 2.8
6.2 50
0.56 3.0
0.4 0.9
2.9 16
0.56 1.95
0.45 1.9
0.12 1.0
0.25 0.8
0.18 40
0.16 17
0.18 6.9
0.43 2.7
0.52 55
0.42 160
0.43 2.4
0.5 1.7
0.5 2.1
0.2 11.0
0.28 17.0
0.4 10.0
0.3 27.0
6 - DuPont Permeator f 7725N
- -
" '
-
~
65 10
330 40
75
360
84.6
87.9
8.0
20.0
3.0 8.0
3.1 20.0
R%
73.1
51.0
77.4
81.3
86.2
75.6
42.9
87.4
77.6
77.5
95.2
83.3
99.6
99.0
99.1
90.4
99.1
99.8
83.5
77.3
86.8
98.5
98.3
96.7
99.1
62.5
84.5
Conductivity
S P
5000 465
4100 360
5200 470
1750 90
1260 270
740 230
925 275
1960 540
1890 550
1730 850
4050 370
4200 610
2750 780
5100 550
2300 240
2000 300
3300 480
3200 340
3250 265
6700 1100
8100 1350
6100 560
3800 650
8600 1600
7600 870
2100 600
1500 310
C Kft
7900 90.7
6200 91.2
6300 91.0
2150 94.9
2600 78.6
1500 68.9
1500 70.3
3200 72.4
2950 70.9
2700 50.9
7000 90.9
5900 85.5
3650 97.5
7200 89.2
3700 89.6
2950 85.0
4300 85.5
4000 89.4
4100 91.8
8000 83.6
9800 83.3
6900 90.8
4600 82.9
10000 81.4
8900 88.6
2700 71.4
1900 79.3
-------
Table C-3. (continued)
Sample
nuiber
118
120
121
124
126
128
129
139
141
142
143
144
149
150
151
153
154
155
158
159
160
162
163
164
167
169
172
179
Operating
tijne(hrs
442
445
452
463
471
503
506
Cycle No.
-
_
_
-
Cycle No.
_
_
_
_
_
Cycle No.
_
_
_
_
_
_
_
_
w
-
Dissolved
S P
.. _
-
-
-
1540 340
-
Solids
C
_
-
_
1985
Color
t*
,^
_
_
_
77.9
_
S
335
1670
3080
240
390
120
175
P
45
215
465
25
60
20
25
C
425
2230
3830
295
490
155
200
Rft
86.6
87.1
84.9
89.6
84.6
83.3
85.7
Turbidity
S
15.0
230
200-
25.0
20
10.0
9.0
P C
3.3 15.0
40 240
80 180
3.5 30.0
5.0 25.0
1.4 11
1.5 9.0
R%
78.0
82.6
60.0
86.0
75.0
86.0
83.3
Conductivity
S
2000
930
3000
940
3100
820
1650
P
485
255
625
250
650
175
405
C R%
2600 75.8
1300 72.6
3800 79.2
1300 73.4
4000 79.0
1000 78.7
2100 75.5
7 - OFNL Module
840 160
1695 220
1125 210
490 65
660 80
-
_
-'
81.0
87.0
81.3
86.7
87.9
480
1100
515
535
525
10
5
4
4
8
-
_
_
-
97.9
99.5
99.2
99.3
98.5
20
20
6.0
80
50
0.2 -
0.27 -
0.43 -
0.47 -
0.4 -
99.0
98.7
92.8
99.4
99.2
1500
2750
1925
780
1050
315
400
380
180
160
79.0
85.5
80.3
76.9
84.8
8 - OPNL Module
2465 945
_ _
_ _
1140 335
_
_
_
_
_
61.7
_
70.6
750
280
325
915
585
635
15
10
10
15
15
20
_
_
_
_
-
98.0
96.4
96.9
98.4
97.4
96.9
5.1
5.8
6.0
35
4.4
3.8
0.8 -
0.4 -
0.4 -
0.5 -
0.4 -
0.46 -
84.3
93.1
93.3
98.6
90.9
87.9
3850
870
940
1625
2100
2350
1725
26Q
28S
560
770
870
55.2
70.1
69.7
65.5
63.3
63.0
9 - OFNL Module
850 155
1285 240
2395 440
1760 295
2965 500
3505 560
4300 780
1320 195
3490 775
1355 445
_
_
_
_
_
..
_
-
81.8
81.3
81.6
83.2
83.1
84.0
81.9
85.2
77.8
67.2
315
670
1420
1165
3500
2960
4400
490
1540
715
1
10
25
4
1
4
10
2
8
8
-
_
-
-
_
_
-
99.7
98.5
98.2
99.7
99.9
99,9
99.8
99.6
99.5
98.9
25
40
60
90
135
140
no
20
25
55
0.4 -
0.6 -
0.65 -
0.55 -
0.35 -
0.4 -
0.65 -
0.35 -
0,35 -
0.4 -
98.4
98.5
98.9
99.4
99.7
99.7
99.4
98.3
98.6
99.3
1200
1950
3230
2700
4100
4900
4600
2150
4600
2150
230
370
715
580
900
1050
1220
410
1300
780
80.8
81.0
77.9
78.5
78.0
78.6
73.5
80.9
71.7
63.7
-------
Table C-3. (continued)
Seof>le
mxber
183
TOO
188
1 /\ *
194
165
1 ftt
168
173
« « .
174
176
177
178
180
182
192
195
203
204
208
209
210
212
218
220
223
225
230
232
235
236
Operating
tine(hrs)
-
'"
"
cycle No.
23
95
143
387
435
502
530
545
Cycle No.
556
701
744
Cycle No.
1
10
22
26
31
48
63
80
105
128
160
165
176
178
Dissolved Solids
S P C
2500 715 -
3475 930 -
3875 1070 -
10 - Westinghouse
- -. -
_
_
- -
-
2280 115 -
3040 255 -
11 - Westinghouse
475 15
4900 225 -
4125 270 -
R*
71.4
73.2
72.4
Module
-
-
-
-
-
-
95.0
91.6
Module
96.8
95.4
93.5
Color
S P
1625 15
3270 8
4150 20
14-291
585 2
990 1
1090 8
1880 3
2840 2
3960 2
2100 50
2710 185
14-291
310 2
920 50
1560 45
C
_
-
_
590
-
_
_
-
-
_
-
R%
99.1
99.8
99.5
99.7
99.9
99.3
99.8
99.9
99.9
97.6
93.2
99.4
94.6
97.1
Turbidity
S
60
45
35
30
20
15
200
230
210
220
230
35
20
0.02
P C
0.55 -
0.35 -
0.30 -
0.35 30
0.4 -
0.28 -
0.4 -
0.3 -
0.35 -
15
40
0.6 -
2.0 -
0.80 -
R%
99.1
99.2
99.1
98.8
98.0
98.1
99.8
99.9
99.8
93.2
82.6
98.3
90.0
Conductivity
S P
3500 1150
4200 1500
4500 1750
1950 100
4100 210
4900 325
2700 140
3650 225
4500 260
2650 190
3400 390
650 50
5300 825
5300 490
12 - DuPont Permeates: 1400600
_
-
- _ _
- - -
-
- - _
- - -
- - -
- _ _
- _ _
_ _ _
- - -
_ _ _
- - -
-
-
_
-
-
-
-
-
-
-
-
-
-
160 2
110 2
575 6
575 2
315 2
225 2
40 2
265 2
1250 2
390 2
725 2
915 2
105 2
590 2
380
195
1100
1080
490
390
45
435
2350
665
1300
1500
160
1100
98.8
98.2
99.0
99.7
99.4
99.1
95.0
99.2
99.8
99.5
99.7
99.8
98.1
99.7
1.5
2.6
2.2
4.8
0.90
1.4
4.5
3.5
1.8
2.1
3.7
6.3
3.0
3.0
0.45 12
0.3 3.6
0.29 0.9
0.33 5.4
0.40 0.70
0.33 1.1
0.36 3.0
0.35 4.0
0.59 2.3
0.62 2.0
0.35 2.0
0.40 5.1
0.38 3.3
0.40 2.5
70.0
88.5
86.8
93.1
55.6
76.4
92.0
90.0
67.2
70.5
90.5
93.7
87.3
86.7
6200 215
2000 60
5600 140
3700 120
5900 210
2150 70
21000 1550
820 25
960 60
4000 275
2400 150
2150 200
980 140
1350 215
C R%
67.1
77.1
61.1
2000 94.9
94.9
93.4
94.8
93.8
94.2
92.8
88.5
92.3
84.4
90.8
8000 96.5
3300 97.0
9000 97.5
6100 96.8
8000 96.4
3700 96.7
23000 92.6
1250 97.0
1575 93.8
6200 93.1
380 93.8
3000 90.7
1500 85.7
2150 84.1
-------
Table C-3. (continued)
CO
CTl
Sanple
205
207
239
246
250
252
254
256
257
258
259
260
262
263
264
272
273
274
277
278
281
282
287
289
290
Operating
4-1 nw* /U_e>l
i-Liit; inrsj
Cycle No
Cycle No.
93
165
193
252
272
316
434
583
631
633
684
708
779
Cycle No.
:
_
~
_
- ,
Dissolved Solids
S
fc «_
10 _ r
P C
_
JKNL Module
R%
14 - Gulf Module
1285 25 1680
1200 70 1520
4950 170 5990
2155 55 2510
16 - Selas Module
970
_
1300
1665
2010
780
1385
1970
-Vi^IMH
no -
150 -
200
115
130 -
180 -
70
115 -
190 -
98.1
94.2
96.6
97.4
88.7
92.2
91.0
91.0
91.7
90.4
Color
S p "
760 205
635 385
135 1
300 2
160 2
40 1
2800 6
2450 6
2460 5
2680 5
2580 10
960 2
445 1
685 1
605 1
635 4
R
- 6
QT; _
- 10
1050 10
1210 15
295 2
490 20
670 30
C
.
180
375
200
45
3710
3290
3300
3340
3150
1165
555
710
710
-
~
R%
^V^B^M^B
73.0
39.4
99.3
99.3
98.8
97.5
99.8
99.8
99.8
99.8
99.6
99.8
99.8
99.9
99.8
99.4
~
~
*
99.0
98.8
99.3
95.9
95.5
THwHiHi t-v
S P C R%
60 25
50 35
1.3 0.55
6.1 0.64
3.6 0.55
1.8 0.5
0.05 0.37
0.02 0.32
0.01 0.30
0.01 0.50
0.01 0.50
35 0.34
4.5 0.22
5.1 0.30
40 0.20
4.7 0.18
0.20
0.36
5.3 -
0.21
6.6 0.31
7.5 0.55
6.3 0.29
8.6 0.3
15 0.45
58.3
30.0
1.35 57.7
6.3 89.5
4.2 84.7
2.2 72.2
0.04 -
0.01 -
0.01 -
0.01 -
0.01 -
30 99.0
4.0 95.1
4.4 94.1
40 99.5
96.2
-
- -
95.3
92.7
95.4
96.5
97.0
Conductivity
S P c R%
2050 770
1950 1250
1300 40
2350 90
1575 60
1350 90
5450 300
5900 290
5500 290
5500 400
5500 360
1575 50
3900 180
5200 165
2550 80
1125 180
295
295
2200 -
290
2450 290
2100 275
1250 160
2350 280
3200 450
62.4
35.9
1820 96.9
2825 96.2
2050 96.2
1775 93.3
6500 94.5
7100 95.1
6700 94.7
6700 92.7
6700 93.5
2000 96.8
4600 95.4
5900 96.8
2800 96.9
84.0
_
* w
88.2
86.9
87.2
88.1
85.9
S - supply to module; P = permeate (or product); C = concentrate (or residue); R = 1 - (P/B) - rejection
All results are in mg/* except conductivity (pmho/cm), color (Pt-Co units), and Turbidity (F.T.U.).
-------
Co
Table G-4. PERFOFMMJCE OP HYPEFFffinWTION MOOUIES IN THE IA FTONCE PILOT PLMJT
Rejection and Absolute Values of Calcium, Zinc, Magnesium, and Copper*
Ssnple
nuifcer
4
7
Operating
tune(hrs)
Cycle No.
7
16
S
Calcium
P C
R% S
Zinc
P C
R%
S
Magnesium
P C
R%
S
t^rffo/f
P C R%
1 - DuPont Pezmeator I7753N
5.0
1.4
0.3 6.0
0.1 17.0
94.0 3.0
92.9 1.7
0.05 4.0
0.06 1.9
98.3
96.5
21.5
0.4
DuPont Peraeator I772SN
12
16
22
23
24
25
26
27
28
29
31
33
35
36
37
39
42
44
46
48
50
52
13
27
37
49
55
61
70
76
84
88
92
Cycle No.
94
102
106
108
119
131
145
150
155
161
170
1.0
2.0
:..o
1.0
1.0
2.0
2.0
2.0
2.0
3.0
2.0
<0.1 2.0
0.5 11.0
<0.1 7.0
<0.1 2.0
<0.1 2.0
<0.1 2.0
<0.1 5.0
<0.1 5.0
<0.1 7.0
<0.1 8.0
<0.1 7.0
>90.0 2.0
75.0 3,8
>90.0 3.7
>90.0 1.6
>90.0 4.3
>95.0' 4.3
>95.0 2.1
>95.0 2.7
>95.0 -
>96.7 -
>95.0 -
<0.02 4,0
0.04 10.4
0.05 6.7
0.02 4.7
0.04 8.3
0.02 6.0
0,06 3.7
0.02 4.0
-
_ _
>99.0
98.9
98.6
98.8
99.1
99.5
97.1
99.3
-
_
_
0.28
0.55
0.59
0.5
0.45
0.77
0.74
0.83
0.50
0.04 38
0.003 2.6
0.002 1.22
0.008 1.6
0.003 2.0
0.002 1.4
0.004 1.1
0.003 1.1
0.003 1.1
0.003 1.3
0.005 1.3
_
99.8
99.3
99.3
98.5
99.5
99.6
99.1
99.6
99.6
99.6
99.0
_
0.3
_
^
0.08
_
^
0.12
0.20
_
0.24
2 - DuPont Penneator #7725N
-
-
-
2.7
8.9
5.6
7.9
-
- -
-
0.7 3.4
- -
0.14 25
0.25 6.9
<0.13 10.8
12.0
2.65
5.0
5.05
3.25
7.50
74,1 1.50
1.70
98.4 -
95.5 3.6
>98.4 2.00
0.26 14.5
0.06 3.50
0.06 11.0
0.08 10.0
0,04 3.80
0.54 11.0
0.06 1.94
0.02 2.60
-
0.06 4.65
0.06 3.20
97.8
97.7
98.8
98.4
98.8
92.8
96.0
98.8
-
98.3
97.0
3.90
3.90
3.40
13.0
4.40
12.8
2.80
5.70
14.6
8.00
13.2
0.16 4.20
0.05 4.30
0.01 5.40
0.09 16.0
0.06 5.30
0.40 18.0
0.03 3.70
0.07 10.1
0.15 24.8
0.10 11.0
0.15 25
95.9
98.7
99.7
99.3
98.6
96.9
98.9
98.8
99.0
98.8
98.9
0.48
0.08
0.36
«.
0.24
0.32
0.32
0.12
0.12
<0.04 0.6 >86.7
_ _ _
0.08 0.16 -
-
<0.04 0.18 >66.7
<0.04 0.44 >80.0
<0.04 0.32 >83.3
0.12 0.56 75.0
<0.04 0.16 >50.0
<0.04 0.52 >88.9
- - -
0.08 0.32 66.7
0.08 0.40 75.0
0.04 0.32 87.5
<0.04 0.20 >66.7
<0.04 0.16 >66.7
-------
Table C-4. Continued)
C
oo
Saqple
lumber
53
55
60
61
65
67
69
71
73
75
77
79
81
82
84
86
88
89
91
94
96
99
101
104
108
116
117
Operating
tiite(hrs)
179
Cycle No.
188
209
217
231
284
326
400
423
427
Cycle No.
24
28
37
41
49
62
148
170
218
Cycle No.
236
251
275
284
305
337
Cycle No.
437
439
Calcium zinc
S P C R% s P
25 0.13 40 99.5 1.78 0.04
3 - DuPont Penneator I7725N
4.2 0.1 5.6 97.6 0.44 0.10
6.6 0.4 8.5 93.9 -
- 14.8 0.1
- 1.56 0.18
1.6 0.2 2.2 87.5 -
- 0.14 0.06
2.2 0.4 3.3 81.8 4.45 0.38
- 1.40 0.24
1.9 0.6 2.7 68.4
4 - DuPont Penneator I7753N
3.9 0.2 6.8 94.9 7.50 0.06
3.9 0.3 4.8 92.3 11.5 0.06
4.5 0.6 5.7 86.7 2.70 0,08
6.9 0.12 9.5 98.3 5.10 0.02
4.0 0.04 5.9 99.0 6.25 0.06
4.2 0.12 5.6 97.1 4.4 0.06
4.0 0.04 5.1 99.0 4.85 <0.02
3.5 0.08 4.3 97,7 5.15 0.04
5.0 0.08 6.1 98.4 1.70 0.12
5 - DuPont Penneator I7753N
7.9 0.16 10.1 98.0 3.0 0.1
17.5 0.12 20.0 99.3 3.4 0.16
7.8 <0.04 8.9 >99.5 3.1 0.10
2.48 0.04 2.88 98.4 3.0 0.08
25.0 0.16 31.5 99.4 11.0 0.08
2.56 <0.04 2.92 >98.4 2.20 0.1
6 - DuPont Penneator 1 7725N
2.0 0.4 3.0 80.0 10.0 1.00
1.0 0.3 2.0 70.0 2.00 0.20
C
2.90
0.64
_
18.0
2.65
0.24
5.20
2.05
-
12.3
14.8
3.50
8.0
11.0
5.5
6.5
6.25
2.06
3.8
3.9
3.5
3.30
14.0
2.3
12.0
2.00
R%
97.8
77.3
_
99.3
88.5
_
57.1
91.5
82.9
99.2
99.5
47.0
99.6
99.0
98.6
>99.6
99.2
92.9
96.7
95.3
96.8
97.3
99.3
95.5
90.0
90.0
Magnesium
S
19
_
6.60
2.02
_
_
2.00
2.80
2.20
5.60
8.00
6.10
7.8
5.6
5.9
4.0
5.1
6.3
9.3
20.6
16.8
10.0
32.4
U.I
15.0
2.00
P
0.21
_
0.05
0.24
_
_
0.44
0.66
0.54
0.08
0.20
0.64
0.08
0.02
0.08
0.02
0.06
0.06
0.2
0.36
0.16
0.17
0.42
0.1
2.00
0.40
C
35
8.80
3.80
_
_
4.80
4.80
4.20
10.2
13.4
10.6
11.6
8.4
8.3
5.9
7.4
7.7
13.0
25.3
19.2
12.6
40.8
14.4
19.0
3.00
R%
98.9
99.2
88.1
_
_
78.0
76.4
75.5
98.6
97.5
89.5
99.0
99.6
98.6
99.5
98.8
99.0
97.8
98.3
99.0
98.3
98.7
99.1
86.7
80.0
S
0.64
1.96
0.08
0.12
0.16
0.20
0.44
_
0.32
_
_
0.76
0.40
1.28
-
-
-
-
-
0.40
-
-
-
-
Copper
P
0.04
<0.04
<0.04
<0.04
<0.04
0.04
0.12
_
0.08
_
_
_
0.04
0.08
0.04
-
-
-
-
-
0.08
-
-
-
-
C R%
1.08 93.8
2.56 >98.0
0.12 >50.0
0.20 >66.7
0.24 >75.0
0.28 80.0
0.76 72.7
_ _
0.48 75.0
.» _
_
_ _
1.24 94.7
_ -
0.56 80.0
1.72 96.9
_ _
-
- '
_
0.5 80.0
_
_
-
-
-------
Table C-4. (continued)
10
Sanple
ruiber
118
120
121
124
126
128
129
139
141
142
143
144
149
150
151
153
154
155
158
159
160
162
163
164
167
169
172
179
Operating
time(hrs)
442
445
452
463
471
503
506
Cycle No.
-
~
Cycle No.
-
Cycle No.
-
-
-
-
-
-
S
1.0
1.0
2.0
1.0
2.0
1.0
1.0
Calciun
P C
0.4 2.0
0.3 1.0
0.7 3.0
0.2 1.0
0.6 2.0
0.4 2.0
0.5 2.0
Zinc
K*
60.0
70.0
65.0
80.0
70.0
60.0
50.0
S
2.00
4.00
8.00
0.40
1.00
4.00
6.00
P
0.40
0.60
1.00
0.20
0.40
0.80
0.90
C
3.00
4.00
10.0
1.00
2.00
8.00
7,00
R%
80.0
85.0
87.5
50.0
60.0
80.0
85.0
7 - ORNL Module
0.36
1.40
0.40
0.84
0.60
<0.04 -
<0.04 -
<0.04 -
<0.04 -
<0.04 -
>88.9
>97.1
>90,0
>95.2
>93.3
1.30
1.00
0.80
3.10
1.20
<0.02
0.04
0.04
0,02
<0.02
_
_
_
>98.5
96.0
95.0
99.4
>98.3
Magnesium
S P
3.00 0.60
4.00 0.50
10.0 2.00
3.00 0.30
5.00 0.90
4.00 0.60
7.00 1.00
1.30 0.06
4.50 0.26
1.80 0.04
2.50 0.02
2.40 0.06
C
5.00
4.00
13.0
3.00
7.00
5.00
10.0
_
_
_
_
_
Comer
^***n
P% S P C R%
80.0 -
87.5 -
80.0 -
90.0 -
82.0 1.0 0.2 1.0 80.0
85.0 - - - -
85.7 - - - -
95.4 -
94.2 -
97.8 -
99.2 -
97.5 -
8 - ORNL Module
5.88
1.40
1.86
4.%
1.64
1.88
0.78 -
0.24 -
0.20 -
0.48 -
.0.32 -
0.16 -
86.7
82.9
89.2
90.3
80.5
91.5
2.71
_
2.35
<0.02
-
0.02
-
_
_
_
_
-.
>99.3
_
99.1
_
_
8.30 1.70
4.50 0.51
5.20 0.53
10.0 1.50
2.00 0.54
2.23 0.35
_
_
m
_
_
_
9 - OFNL Module
1.16
1.68
3.12
2.56
5.82
4.32
8.00
0.80
4.32
2.66
<0.04 -
<0.04 -
<0.04 -
0.04 -
0.06 -
<0.04 -
0.08 -
<0.04 -
0.04 -
0.09 -
>96.6
>97.6
>98.7
98.4
99.0
>99.1
99.0
>95.0
>99.1
96.6
1.16
-
2.60
2.32
-
7.92
13.2
-
-
3.00
0.02
-
<0.02
<0.02
-
0.02
0.02
_
-
0.04
-
-
_
-
-
98.3
>99.2
>99.1
>99.7
>99.8
_
_
98.7
2.00 0.09
2.92 0.16
4.80 0.33
4.5 0.17
9.67 0.30
8.00 0.08
13.0 0.38
_ _
6.30 0.21
3.76 0.28
_
_
_
_
_
_
_
_
_
-
79.5 -
88.7 -
89.8 -
85.0 -
73.0 -
84.3 -
95.5 -
94.5 _
93.1 -
96.2 -
96.9 -
99.0 ~
97.1 -
96.7 -
92.6 -
-------
Table c-4. (continued)
Sarple
nurtber
183
188
194
165
168
173
174
176
177
178
180
182
192
195
203
204
208
209
210
212
218
220
223
225
230
232
235
236
Operating
time(hrs)
-
Cycle No.
23
95
143
387
435
502
530
545
Cycle No.
556
701
744
Cycle No.
1
10
22
26
31
48
63
80
105
128
160
165
176
178
S
12.6
19.1
38.2
Calcium
P C
0.11 -
0.48 -
0.60 -
10 - Westinghouse
2.22
6.24
8.32
1.97
2.43
2.86
2.29
0.24
0.12 2.68
0.16 -
0.16 -
0.03 -
0.03 -
0.09 -
0.17 -
0.50 -
11 - Vfestinghouse
0.10
8.40
4.20
0.08 -
0.50 -
0.40 -
R%
99.1
97.5
98.4
Module
94.6
97.4
98.1
98.5
98.8
96.9
92.6
-
Module
92.7
94.0
90.5
S
12.0
24.0
21.1
#4-291
8.00
21.2
25.8
21.6
27.6
38.8
21.2
26.8
#4-291
3.92
30.8
6.80
Zinc
P C
0.04 -
0.07 -
0.08 -
0.04 8.28
0.19 -
0.22 -
0.12 -
0.06 -
0.12 -
0.72 -
2.00 -
0.20 -
0.24 -
0.26 -
R%
99.7
99.7
99.6
99.5
99.1
99.1
99.4
99.8
99.7
96.6
92.5
94.9
99.2
96.2
12 - DuPont Penteator #400600
7.90
2.90
5.40
8.20
4.50
3.10
4.00
1.60
0.86
3.20
3.30
3.60
6.90
7.10
0.20 31.0
0.03 5.00
0.17 9.60
0.09 16.0
0.07 8.40
0.05 5.30
2.50 7.10
<0.03 2.90
<0.03 0.98
0.06 5.60
0.05 6.50
0.06 6.20
1.30 11.0
1.40 15.0
97.5
99.0
96.9
98.9
98.4
98.4
37.5
>98.1
>96.5
98.1
98.5
98,3
81.2
80.3
5.90
1.80
1.10
2.60
5.10
6.40
2,90
1.50
3.00
1.50
3.00
14.0
6.00
3.20
0.02 11
0.04 2.60
0.02 2.80
0.02 5.10
0.05 7.40
0.02 8.00
0.20 3.60
0.02 2.80
<0.02 4.90
0.02 2.40
<0.02 4.90
0.02 21.0
1.70 7.80
0.36 4.60
99.7
97.8
98.2
99.2
99.0
99.7
93.1
98,7
>99.3
98.7
>99.3
99.9
71.7
88.8
Magnesium
S
7.70
16.0
19.6
5.00
15.8
19.0
14.2
1.96
28.8
15.6
19.0
2.92
31.6
11.2
3.50
2.80
2.50
3.10
1.80
5.30
5.80
4.50
7.40
5.50
3.40
26.0
14.0
10.0
P
0.70
1.22
1.60
0.03
0.11
0.18
0.08
0.12
0.22
0.54
1.44
0.04
0.50
0.38
0.01
0.02
0.01
0.02
0.05
0.02
1.20
<0.02
0.02
0.03
<0.02
0.08
0.20
0.78
C
-
5.33
^_
m_
_
_
9.60
5.10
5.40
6.40
3.40
7.10
7.50
9.30
12.0
9.60
7.30
39.0
20.0
16.0
R% S^
90.9 -
92.4 -
91.8
99.4 -
99.3 -
99.1
99.4
93.9
99.2 -
96.5
92.4
98.6
98.4 -
96.6 -
99.7 -
99.3 -
99.6
99.4 -
97.2 -
99.6
79.3 -
>99.6 -
99.7 -
99.5 -
>99.4 -
99.7 -
98.6 -
92.2 -
Copper
P C R%
_
-
- _ _
- _ I
- - _
-
- --- _
- - _
-
V
_ _ _
- - _
^ ^^
- - _
- - _ '
-m
- - _
_ _ _
_ _ _
« «
-
~ _
-------
Table C-4. (continued)
Sanple
ranker
205
207
239
246
250
252
254
256
257
258
259
260
262
263
264
272
273
274
277
278
281
282
287
289
290
Operating
ti»e(hrs)
Cycle No.
-
Cycle No.
93
165
193
252
272
316
434
583
631
633
684
708
779
Cycle No.
-
-
Calcium
S P C
13 - CTOIL Module
_ _ _
_
14 - Gulf Module
4.40 0.06 6.50
6.60 0.16 10.0
9.60 0.06 12.6
11,6 0.09 16.2
8.80 0.04 16.0
8.40 0.04 12.0
11.0 0.04 12.0
9.80 0.04 12.0
11.0 0.04 13.0
5.20 0.04 6.60
10.8 0.04 12.5
15.0 0.04 17.0
3.60 0.10 4.00
16 - Selas Module
3.50 0.07 -
0.10 -
0.12 -
5.10 -
0.07 -
6.00 <0.03 -
7.70 0.08 -
5.20 0.05 -
10.2 0.13 -
14.2 0.20 -
R%
_
_
98.6
97.6
99.4
99.2
99.5
99.5
99.6
99.6
99.6
99.2
99.6
99.7
97.2
98.0
-
-
-
-
>99.5
99.0
99.0
98.7
98.6
S
_
w
1,20
1.30
0.22
0.09
0.84
0.40
0.10
0.12
0.08
0.58
1.80
5.80
3.04
1.20
-
-
1.20
-
1.40
1.50
0.94
1.40
1.90
Zinc
P C
*
mm _
0.03 1.60
<0.02 1.60
<0.02 0.27
<0.02 0.08
<0.02 0.88
0.02 0.47
0.02 0.06
<0.02 0.04
<0.02 0.02
<0.02 0.62
<0.02 2.10
<0.02 6.80
0.04 3.72
0.04 -
0.04 -
0.05 -
- -
0.02 -
0.02 -
<0.02 -
0.03 -
0.05 -
0.02 -
R%
_
^
97.5
>98.5
>90.9
>77.8
>97.6
95.0
80.0
>83.3
>75.0
>96.6
>98.9
>99.7
98.7
96.7
-
_
98.6
>98.7
96.8
96.4
98.9
S
_
fm
5.90
7.00
3.90
4.40
18.0
17.0
16.0
14.0
13.0
7.00
10.0
19.0
13.0
3.40
_
_
4.40
5.10
6.70
4.40
7.50
11.0
Magnesium
P C
_ _
_
<0.02 8.80
0.02 9.20
0.03 5.30
0.03 6.00
0.04 22.0
0.04 22.0
80.0 21.0
<0.02 16.0
0.04 15.0
<0.02 10.0
<0.02 12.0
<0.02 23.0
0.02 15.0
0.10 -
0.13 -
0.19 -
_ _
0.07 -
0.07 -
0.14 -
0.04 -
0.14 -
0.26 -
R%
_
_
>99.7
99.7
99.2
99.3
99.8
99.8
99.9
>99.9
88.7
>99.7
>99.8
>99.9
99.8
97.1
_
_
_
_
98.6
97.9
99.1
99.5
97.6
S
2.40
0.24
0.12
0.20
0.48
0.60
0.40
0.24
0.12
2.40
0.26
4.80
1.10
w
_
_
_
_
mm
_
_
"*
GODDST
w***x
P C R%
0.08 3.28 96.7
<0.04 0.36 >83.3
<0.04 0.12 >66.7
<0.04 0.22 >80.0
0.04 0.62 91.7
<0.04 0.64 >93.3
0.40 0.48 >90.0
0.04 0.36 83.3
0.04 0.20 66.7
<0.04 3.00 >98.3
<0.04 0.36 >84.6
0.04 6.60 99.2
<0.04 1.40 >96.4
mm
mm mm mm
mm mm _
mm _
*
* .. .
mm mm
mm mm mm
S = supply to module; P = permeate (or product); C = concentrate (or residue); R = 1 - (P/S) - rejection
All results are in mg/l.
-------
10
Table C-5. PERTOBMANCE OF HYPERFILTRATION MODULES IN THE LA. FRANCE PILOT PLANT
Rejection and Absolute Values of Iron, Sodium, Sulfate, and Suspended Solids3
Sample
ranter
4
7
12
16
22
23
24
25
26
27
28
29
31
33
35
36
37
39
42
44
46
48
50
52
Operating
time(hrs)
Cycle No.
7
16
13
27
37
49
55
61
70
76
84
88
92
cycle No.
94
102
106
108
119
131
145
150
155
161
170
S
Iron
p
C
R%
S
1 - DuPont Perneator £7753N
- - - - 1500
DuPont Penneator #7725N
<0.3 <0.3 1.0 -
<0.3 <0.3 0.3 -
- 2.32
-
<0.2
_
<0.2
<0.2
<0.2
-
-
<0.2
_
_
CO
<0
<0
-
.2
.2
.2
_
<0.2
_
_
<0.2
<0.2
<0.2
_
_
_
^
--
M
_
_
300
335
_
_
^
^
w
Sodium
P
90
21
25
30
_
_
_
C
2800
640
745
780
_
^
_
_
Sulfate
R% S P C R%
94.0 -
90.0 -
91.7 -
91.0 -
- _
- - _ _
Suspended Solids
S P C R%
-
- - _
- - _ _
- - I I
2 - DuPont Penneator #7725N
0.63
-
0.38
0.25-
-
<0.13
0.13
-
-
-
<0
_
-
0.
<0
<0
<0
-
-
-
.13
13
.13
.13
.13
0.88
_
-
0.50
0.38
-
<0.13
0.25
-
-
-
>79.4
_
65.8
>48.0
_
_
_
-
-
-
_
_
640
_
_
_
_
780
400
-
_
_
50
_
_
_
_
_
80
40
-
_
_
1040
_
_
_
_
1040
600
. « _
^ m
92.2 -
»
v ~
^ ^
-
89.7 -
90.0 - -
_ _
- - _
I I
^ ^
- - _ _
- - _
- _
- - - _
" » ^ ^
- - -
» ^
-------
Table c-5. (continued)
U)
Sanple
nunfcer
53
55
60
61
65
67
69
71
73
75
77
79
81
82
84
86
88
89
91
94
96
99
101
104
108
116
117
118
Operating
time(hrs)
179
Cycle No.
188
209
217
231
284
326
400
243
427
Cycle No.
24
28
37
41
49
62
148
170
218
Cycle No.
236
251
275
284
305
337
Cycle No.
437
439
442
Iron
S P C R
- - _ _
3 - DuPont Perneator
- - - _
-
<0.1 <0.1 <0.1
0.1 <0.1 0.2 -
<0.1 <0.1 <0.1 -
<0.1 <0.1 0.1 -
- _ _ _
<0.15 <0.15 <0.15 -
- - _ _
4 - DuPont Permeatar
- - _ _
- - ~ -
-
- - _ _
-
_ _ _
- - _ _
-
- - _
5 - DuPont Permeator
-
- _ _ _
- _ _ _
- - _ -
- _ _ _
_ _ _ _
Sodiim
% S
760
#7725N
560
1060
.. .
.
220
360
400
360
$775311
780
840
580
_
320
140
620
620
720
#7753N
1260
1720
1140
590
1740
1280
P
65
45
125
fm
^
75
_
105
180
175
105
115
150
_
45
45
80
75
60
250
230
100
100
240
150
C
5120
860
1240
^
^
300
_
680
520
660
1600
1220
660
_
680
480
800
960
940
1600
2040
1300
720
2125
1480
Sulfate
R% S P C R%
91.4 -
92.0 -
88.2 -
I
65.9 -
70.8 -
55.0 - - - -
51.4 -
86.5 -
86.3 -
74.1 -
86.0 -
67.9 -
87.1 -
87.9 -
91.7 -
80.2 -
86.6 -
91.2 -
83.1 -
86.2 -
88.3 -
Suspended Solids
S P C R%
_ _ _
- _ _ _
_ _ _ _
-
I I
- - - _
i ^
^ ^ »
- - _ _
^
»
~ »
" *»
*
*.
6 - DuPont Permeator #7725N
_ _ _ _
_ _ _ _
- _
340
230
310
100
50
80
430
315
450
70.6 -
78.3 -
74.2 - - - -
» ^ ^
_ _
_ m*
-------
Table C-5. (continued)
Sample Operat
nunber time (hi
120 445
121 452
124 463
126 471
128 503
129 506
Cycle
139
141
142
143
144
H Cycle
£ 149
150
151
153
154
155
Cycle
158
159
160
162
163
164
167
169
172
179
183
ing Iron
°t i> P C
__
No. 7 - OFNL Module
4.0 <0.1 -
26 <0.1 -
No. 8 - ORNL Itodule
8.0 <0.1 -
0.5 <0.1 -
2.0 <0.1 -
22.0 <0.1 -
1.0 <0.1 -
4.0 0.1 -
No. 9 - OKNL Module
6.67 <0.11 -
17.8 <0.11 -
5.00 <0.13 -
31.0 <0.13 -
R%
^-^^ .^^^
>97.5
>99.6
>98.8
>80.0
>95.0
>99.5
- >90.0
97.5
>98.4
>99.4
>97.4
>99.6
S
180
480
175
500
150
275
290
610
330
130
195
800
160
170
290
455
470
265
400
800
580
920
1080
1230
390
1250
465
670
Sodium
P C
R%
S
Sulfate
P C
Suspended Solids
R%
S
P
C R%
35 240 80.6 ---_ -___
110 620 77.1 --__ -___
40 210 77.1 ---_ -___
110 765 78.0 --__ ____
35 255 76.7 --__ ____
65 310 76.4 --__ -___
55 - 81.0 --__ ____
85 - 86.1 -___ -___
70 - 78.8 ---_ -___
25 - 80.8 ---_ - _ _ .
30 - 84.6 - - - - ._ _ __
390 - 51.3 ---_ --__
45 - 71.9 --__ --__
55 - 67.6 - _
115 - 60.3 --__ -___
150 - 67.0 --__ --__
175 - 62. R
55
75
150 -
95
165 -
185 -
270 -
75
255 -
130 -
215 -
79.2
81.3
81.3
83.6
82.1
82.9
78.0
80.8
79.6
72.0
67.9
57
63
128
64
253
240
555
150
615
2,3 -
2.3 -
8.9 -
9.6 -
30
30
55
2
30
96.0
96.3
93.0
85.0
88.1
87.5
90.1
98.7
95.1
15
5
5
145
265
400
370
40
65
30
45
~
0
0
0
0
0
0
0
15
25
0
10
*""
100
100
100
100
100
100
100
62.5
61.5
100
77.8
-------
Table C-5. (continued)
Ln
Sanple
ranter
188
194
165
168
173
174
176
177
178
180
182
192
195
203
204
208
209
210
212
218
220
223
225
230
232
235
236
205
Operating
time(hrs)
-
-
Cycle No.
23
95
143
387
435
502
530
545
Cycle No.
556
701
744
Cycle No.
1
10
22
26
31
48
63
80
105
128
160
165
176
178
Cycle No.
-
b
-
10
-
-
-
-
-
-
-
-
JJ.
-
-
-
12
-
-
-
-
-
_
-
-
-
-
-
-
-
-
13
16
Iron
P C
_
- -
- Westinghouse
- -
- - '
- -
- -
-
-
- -
-
- Westinghouse
- -
-
- -
Sodium
R%
_
-
Module
-
-
-
-
-
-
-
-
Module
-
-
-
S
U70
1360
#4-291
370
1130
1140
745
1280
1520
695
720
14-291
170
1855
1600
P
330
470
14
20
55
25
35
65
30
60
2.5
65
80
C
_
375
-
-
_
-
-
-
-
-
-
Sulf ate Suspended Solids
R% S P
71,8 -
65.4 -
96.2 -
98.2 -
95.2 -
96.6 -
97.3 -
95.7 -
9S.7 -
91.7 -
98.5 -
96.5 -
95.0 -
c R% s
40
- - 75
_ _ _
_ _
_ _ _
_ _ _
_ _ _
- - 85
- - 75
_ _ _
_ _
_ _ _
P
0
10
_
-
_
-
0
0
-
-
-
C R%
100
86.7
_
_ _
-
100
100
-
-
-
- DUPont Permeator 1400600
- -
- -
- -
- -
- -
_ _
-
-
- -
-
- -
_ _
- -
-
- QRNL Module
.9 3.8 -
-
-
-
-
-
-
-
-
-
-
-
-
-
77.5
1760
400
1390
815
1425
520
6080
210
250
1070
745
625
255
360
-
65
5
25
14
30
7
385
3
7
60
35
60
30
50
-
3280
745
2945
1600
2135
1120
7520
360
390
1705
1120
895
410
570
-
96.3 -
98.8 -
98.2 -
98.3 -
97.9 -
98.7 -
93.7 -
98.6 -
97.2 -
94.4 -
95.3 -
90.4 -
88.2 -
86.1 -
- - -
_ _ _
_ _ _
_ _ _
_ _ _
_ _ _
_ _ _
_
_ - _
_ _ _
_
- - -
_ - -
_ - _
_ _ _
-
-
-
-
-
-
-
-
-
-
-
-
-
-
- -
- -
- -
-
-
- _
- -
- -
-
-
-
-
- -
-
-------
Table C-5. (continued)
Sanple
ranter
207
239
246
250
252
254
256
257
258
259
260
262
263
264
272
273
274
277
278
281
282
287
289
290
Operating
time(hrs)
H
cycle No.
93
165
193
252
272
316
434
583
631
633
684
708
779
Cycle No.
-
-
-
-
-
-
-
"
Iron
S P C R%
11.9 6.0 - 49.6
14 - Gulf Module
<0,17 <0.17 <0.17 -
<0.17 <0.17 <0.17 -
<0,17 <0.17 <0.17 -
2.20 <0.17 3.30 >92.3
<0.17 <0.17 <0.17 -
<0.17 <0.17 <0.17 -
<0.17 <0.17 <0.67 -
<0.17 <0.17 3.30 -
<0.17 <0.17 <0.17 -
<0.17 <0.17 0.67 -
<0.17 <0.17 <0.17 -
<0.17 <0.17 <0.17 -
<0.14 <0.14 <0.14 -
16 - Selas Module
_ _ _ -
_ _ _ -
- - - -
- - - -
_ _ - -
_ _ _ _
- - - -
- - -
.
Sodiixn
S
_
350
655
440
390
1620
2175
1855
2175
1825
465
1310
1345
335
~
-
P
5
20
10
20
60
45
60
65
60
9
30
35
15
~
-
C
-
495
830
600
495
1890
2495
2335
2400
2210
610
1570
1730
800
""
~
~
~
Sulfate
Ri S P C R%
_
98.6 - - - -
96.9 .- -
97.7 - - - -
94.9 - - - -
96.3 -
97.9 - - - _ -
96.8 - - - -
97.0 - - - -
96.7 - - - -
98.1 - - - -
97.7 - - - -
97.4 - - - -
95.5 - - - -
_ _ - - -
_
_
w
_ - - - -
^
^ ^ " **
^ ^ ^
^ ^
Suspended Solids
S P C R%
_
^ ^
-»
«.
_
" ^ ^
^ ^ ^
^ ^ ^ ^
«i **
~ "
.
« ~ ""
^ ^
_ .
a S = supply to nodule; P = penneate (or product); C = concentrate (or residue); R = 1 - (P/S) = rejecticn
b All results are in mg/i.
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
\. REPORT NO.
EPA-600/2-76-060
2.
3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
Hyperfiltration for Renovation of Textile Finishing
Plant Waste water
5. REPORT DATE
March 1976
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
Craig A. Brandon and John J. Porter
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING OR3ANIZATION NAME AND ADDRESS
LaFrance Industries
Riegel Textile Corporation
LaFrance, SC 29656
10. PROGRAM ELEMENT NO.
1BB036; ROAP 21AZT-006
11. CONTRACT/GRANT NO.
Grant S800929
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPOHT AND PERIOD COVERED
Final; 7/72-8/75
14. SPONSORING AGENCY CODE
EPA-ORD
15. SUPPLEMENTARY NOTES pr0ject officer for this reportis T.N.Sargent, ERL-Athens,
IB. ABSTRACT
repOr£ gives results of experimental work showing that wastewater from
a textile dyeing and finishing operation can be recycled. The wastewater was run
through a set of hyperfiltration membranes , which separated it into purified water
and a very concentrated dye residue fraction. Over the 15-month evaluation, up to
90% of the wastewater was recovered and was found to be a satisfactory substitute
for the normal water supply in all parts of the dyeing operation. A total of 1,348
meters of first quality fabric was produced during this period. The concentrated dye
residue can also be used to dye fabric in the dyeing operation. The cost of recycling
the wastewater was projected to be #0.121 per cubic meter of wastewater. However,
reusing the wastewater results in a potential savings of $0.234 per cubic meter,
offsetting the operating cost. The textile industry presents an excellent opportunity
for recycling industrial wastewater after treatment with hyperfiltration membranes.
The direct recycle will achieve pollution abatement with significant reduction in
operating costs brought about by savings in water, chemicals, and energy. Results
are being studied further by EPA at several other textile plants in cooperation with
the South Carolina Textile Manufacturers Association and Clemson University.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
c. cos AT i Field/Group
Pollution
Textiles
Textile Processes
Dyeing
Finishing
Waste Water
Circulation
Filtration
Cost Effectiveness
Pollution Control
Stationary Sources
Recycling
Hyperfiltration
13B
HE 07D
13H 14A
18. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (ThisReport)
Unclassified
155
,GES
2O. RFCURITY CLASS fTliit navel
22. PRICE
Unclassified
EPA Form 2220-1 (9-73)
T4T
------- |