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The Future of Zero Liquid Discharge Method for Water Management at Industrial Site

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Over the past years, the recovery, recycling and reuse of wastewater has become a major trend as well as an inescapable need globally. Amidst the steadily increasing environmental concerns, scarcity of freshwater and stringent regulations, industries are in constant search of the best method of wastewater treatment. Though Zero Liquid Discharge (ZLD) methods have been in use at industrial sites for quite some time now, there have been multiple challenges. 

Challenges for ZLD at industrial sites

1. The conventional methods of ZLD using thermal evaporators, (though effective) are a challenge in terms of the economic and energy aspect. This method is highly energy consuming and requires huge capital investment. 

2. Innovative and customized ZLD solutions for different types of industries developing effective high recovery systems capturing different types of effluent composition has been a challenge.

3. Ideal operating conditions for ZLD, including temperature, pressure, scaling, and susceptibility to foul need close monitoring.

4. Choosing the right kind of evaporator effects for a system with several effects is a challenge.

5. Effluent characteristics along with related corrosion and temperature issues and challenges of material compatibility have been leading to high operating costs for ZLD treatments. 

What the future holds for Zero Liquid Discharge?

New developments and innovations in the ZLD methods are not only promising solutions for industrial sites like textile, pharmaceuticals, electronics and minerals etc. but also becoming a global favourite for industrial water treatment. The emerging membrane-based ZLD technology has been cutting the cost as well as beating the energy requirement resulting in effective treatment of Condensate Polishing Unit. 

#1. To minimise the price of ZLD systems, more dependable, higher recovery MLD (Minimal Liquid Discharge) processes must be achieved first, which requires advanced RO (Reverse Osmosis) elements designed to handle difficult brine fluids.

#2. After the RO step, three membrane based processes namely, ED (Electrodialysis), FO (Forward Osmosis), and MD (Membrane Distillation) have proved to be effective alternative ZLD technologies to brine concentrators for further concentration. These procedures generate brine, which is used as a feed for the crystallizer or evaporation pond.

Analysis of the benefits, drawbacks, and energy requirements of these processes show that the final result is perfect for regulatory compliances and hence outweighs the economic constraints. These technologies are advanced methods that combine heat and membrane based techniques in some cases, such as thermolytic FO and MD. Although heat energy is used in these processes, the main separating elements of these technologies are membranes.

Zero Liquid Discharge Plant Technology

Zero liquid discharge (ZLD) technology typically involves a combination of several treatment processes, depending on the composition of the wastewater and the desired level of treatment. Here are some of the common steps involved in a ZLD plant:

1. Pre-treatment: In this step, the wastewater is screened and pre-treated to remove large solids and debris, and to adjust the pH and temperature of the wastewater to optimize subsequent treatment processes.

2. Reverse osmosis (RO): The wastewater is then treated using an RO system, which uses a semi-permeable membrane to remove dissolved solids, organic compounds, and other contaminants from the water. The permeate, or treated water, is then collected and sent for further treatment or reuse.

3. Brine concentration: The concentrate, or brine, that is left behind from the RO process is then sent to a brine concentrator, where the water is evaporated and the remaining salts and solids are concentrated and separated.

4.Crystallization: The concentrated brine is then sent to a crystallizer, where the remaining salts and solids are further concentrated and crystallized, producing a solid waste stream.

5. Solids dewatering: The solid waste stream is then sent to a dewatering system, such as a filter press or centrifuge, to remove any remaining moisture and produce dry solid waste that can be disposed of.

From the environmental sustainability point of view and compliance requirements for industrial sites, Zero Liquid Discharge Plant is one of the best methods to adopt. ZLD has a tremendous deal of potential to reduce water pollution and increase water supply, but its practicality depends on striking a balance between the advantages of ZLD, energy consumption, and initial as well as operating expenses. To get the best out of this amazing innovation, the best technologist needs to be in charge to ensure appropriate installation and proper management. A3 Techno Crafts is a leading technologist working with various site based customised ZLD plants across industries. Technologists like A3 Techno Crafts, perform accurate analysis of the generated effluents and other crucial factors for a particular site and find the best possible solution. Both energy consumption and costs are minimised with proper research before installation combined with the use of methods equipped with advanced innovations.

Water Management in textile industry: Impurities and water softening

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Water management is the movement of water resources and controlling them for reducing the damage to property and life. Another purpose of water management is to maximize efficient beneficial use. In the textile industry, water management is the procedure of planning, developing, and distributing as well as management of proper water resource usage. Waste water treatment is the sub-set of water cycle management. 

In the textile industry, water is used in addition to many chemicals and hard particles. This brings many impurities into the water which are then sent to the water resources after being used. The main chemicals that are added to water are carbonate, sulfate, chloride, bicarbonate, potassium, calcium, and iron. These impurities are mixed in water which pollutes this natural and tremendously evitable source.

Impurities in Water

There are several types of impurities in water. These are briefly described below

1. Physical Impurities – The physical contaminants added to water affect the physical properties of water. The main examples of physical contaminants in water are organic material, and sediments and these affect the taste, color, odor, and conductivity of water.

2. Chemical Impurities – Chemical impurities get into the water when different chemicals and gases are mixed in water. For example, CO2, O2, NH3, pH, minerals, and other ions.

3. Biological Impurities – Bacteria, viruses, dissolved solids, industrial wastes, and chlorine are the main biological impurities in water. The detrimental effect they have on the water is tremendous. Reverse osmosis water treatment is the most effective solution for removing contaminants from water.

Water Hardness and Its Types

As a lot of materials are dissolved in water, water hardness is particularly the amount of dissolved magnesium and calcium in the water. Even in the textile industry, hard water can’t be used. So, it has to be softened before using it in clothing making. 

Types of hard water

1. Permanent hardness – When nitrate and sulfate salts of magnesium and calcium are present in water, then it is called permanent hardness. Boiling is not sufficient for removing this kind of hardness.

2. Temporary hardness – When water contains carbonate or bicarbonate salts of magnesium and calcium in the water, then it is termed temporary hard water. The name- temporary hardness; shows that this hardness goes by just boiling the water.

Water Softening

The process of removing hardness – causing ions from water is called water softening. Mostly, iron ions, calcium, and magnesium ions can be removed with the process. Ion-exchange is one of the most conventional water softening techniques where hardness ions change their places with chloride and sodium bounded with an ion-exchange zeolite and resin. There are many more water chemicals that can be treated with the process of water softening. Types of water softeners are mentioned below-

1. Non-Ionic Softeners – Non-ionic softeners include ethoxylated products, paraffin, polyglycol, and fats. These are less efficient as compared to cationic, and anionic softening agents. But non-ionic softeners stay stable in presence of anions, and cations and withstand the effects of a basic or acidic environment and hard water.

2. Anionic Softeners – Anionic softeners are generated by the condensation of fatty acids. Anionic softeners have good characteristics similar to that of lubricating softening agents. These softeners are not able to stand in water and acidic environments. 

3. Cationic Softeners – Cationic softeners are amino-esters, ammonium salts, and amino amides. These softeners are suggested for all forms of fibers. The exhaustion process is used to apply these softeners in an acid environment where the pH value is between 4 to 5.

Understanding Zero Liquid Discharge (ZLD) Plant and its functions

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Zero Liquid Discharge (ZLD) as the name suggests is a process designed to achieve zero liquid status in the waste generated or a method to eliminate waste liquid completely. Main driving force behind this is to minimize water wastage and maximize its usage through recycling. This proves beneficial for the environment and economy by saving gallons of Zero Liquid Discharge Plant.

Industrial wastewater contains a lot of harmful biodegradable or non-biodegradable substances which are unfit to be discharged into water bodies. Harmful effluents and discharges from the industries are threatening the environment. We all know water is very scarce in many parts of the world. Saving water is a growing concern for which various measures like regulating the way water is used have been taken around the world. ZLD uses advanced technologies in water treatment plants to purify wastewater.

Design of a Zero Liquid Discharge Plant (ZLD) plant

ZLD plant is designed and customized according to the site where it is needed. It is mostly needed for industries which depend a lot on water for their operation and process. There are various factors that needed to be thought of before a ZLD can be installed. The byproducts of ZLD operation are liquid and solids, out of which water is used again for various processes and the solid part is discarded in landfill or treated further to extract chemicals if possible.

Government regulations these days have made it mandatory for different industries like textiles, chemicals and beverage industry to have ZLD installed so as to reduce Waste water treatment. Water recovery is the most important function of a ZLD plant. It is important to have a reliable ZLD plant to adhere to strict norms of regulations set by the government.

The ZLD processing plant constitutes physicochemical treatment, biological treatment, membrane filtration and evaporation concentration. A well designed ZLD plant handles variable volumes and speed of discharge, delivers solid waste for disposal and recovers more than 90% of liquid for further usage. Although a bit costly, it goes a long way in managing water resources wisely.

A3 is a leading system integrator offering engineering solutions for wastewater treatments. We provide customized, reliable and efficient solutions for ZLD to help you meet your corporate responsibilities. We understand your needs and come up with best possible solutions that suit your industry type. Minimize water wastage and optimize water to its maximum potential with effective ZLD plants from A3 Technocrafts.

Technicalities of Water Conservation at Industrial Sites

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There was a time when nature had its own ways of purifying waste water and regenerating water resources. However, with increasing population and industries, and decreasing water bodies, the natural regeneration process was not enough. Therefore, it is of utmost importance that responsible industrial powers take these steps to extend a helping hand to mother earth towards achieving sustainability. Ignoring or delaying the installation of waste water treatment plants could negatively affect industrial productivity and profit.

Leading technologists like A3 Techno Crafts assist the industries to install industrial water treatment plants using suitable technology. From surveying the sites to researching the nature of effluents and installing treatment plants with appropriate technology and assisting with the necessary maintenance.

Techniques used to treat industrial wastewater vary depending on the nature of the industry, effluents released, and possibilities of reuse. Let’s have a look at the various plants A3 Techno Crafts installs:

1. Effluent Treatment Plants (ETP): Depending on the type of effluents and site of generation ETPs purify wastewater in different stages of treatment such as physico-chemical treatment, biological treatment, and tertiary treatment. A3 Techno Crafts’ ETPs are crucial for food & pickling, pharmaceutical, chemical, paint, textile, and manufacturing industries, etc to clean the industrial effluent.

2. Sewage Treatment Plants (STP): The wastewater treated with Activated Sludge Process (ASP) technology of A3 Techno Crafts’ STPs can be reused on the site. Resorts and institutions; food, dairy, tobacco, chemical, and textile industries greatly benefit from such plants.

3. Zero Liquid Discharge Plants (ZLD):  A3 Techno Crafts’ ZLD plants are one of the best-known methods to guarantee compliance with manufacturing specifications while meeting the regulatory compliance requirements. Moreover, a range of industries including oil, ceramics, plastic, metal, and wood require ZLDs installed on-site for maximum water recovery.

4. Industrial Ultra Filter System: Innovative A3 technology makes it possible to utilize alternative raw water from sources like surface or well instead of only tap water with an ultrafiltration system. This automated filtration process is definitely a cost-saving and sustainable method for any industry. A3 ultrafiltration involves low operating cost, low energy consumption, and low chemical use.

5. Integrated STP and ETP System: A3’s combined plants for effluents and sewage treatment are an added bonus especially for hotels, resorts, and corporate industries  Be it environmental concerns, pollution compliances, or responsible use, water conservation has become a need for every industrial site. Begin a collaborative journey with the leading technologist A3 Techno Crafts and treat the wastewater in industrial sites for your benefit. With successful businesses and offices worldwide, A3 is creating nothing less than a revolution in the field of water conservation. Associate with A3 and adopt smart water solutions for a sustainable future. Consult A3 Techno Crafts to find out a suitable wastewater treatment plant for your industry. Know more: https://a3technocrafts.com/products/waste-water-treatment/

Crisis to Conservation Do your bit to reduce water crisis, with A3 Techno Crafts

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Be it any civilization, from ancient to modern, water has always been the lifeline of human lives. In all the ancient philosophies about basic elements, water is inseparable. No matter how much we are technologically advancing, we cannot create water. Technology combined with willing & responsible hands can only save the existing sources. 

Thus, our best bet is to reuse, recycle and conserve.

There is an impending water crisis the whole world will be facing if the right steps are not taken urgently. According to the World Water Development Report prepared by the United Nations, around 1.8 billion people will be living in regions with sheer water scarcity by 2025. And by 2030, it will be half of the world population. 

Water crisis essentially means a scarcity of water. With the increasing global population, uneven distribution of water sources, and unequal pattern of water uses, there is a serious mismatch between availability and demand for freshwater. As this divide is increasing fast, the world is heading towards a major crisis. With rapid urbanization along with growing agricultural and industrial uses, water sources are fast depleting. Climate change, deforestation, and rising levels of pollution are making it difficult for conservation efforts to work efficiently. 

Water conservation on the other hand refers to a sustainable move towards reviving and conserving natural sources of water through activities, strategies, and policies. It is a dire need in today’s time as the crisis is not far away. 

How technology can intervene in reducing the impending crisis

Technology plays a crucial role in water conservation. With physical, chemical, and biological processes, wastewater with contaminants is treated for further use or safe release to the environment. Wastewater treatment plants are a major part of water conservation technology. Wastewater processing includes processes that are primary, secondary, and tertiary. While primary and secondary are initial separation processes, tertiary is the final process releasing safe water for reuse. 

How A3 Techno Crafts is leading the vision?

From personal uses to industrial plants and smart cities, effective water management techniques are useful, cost-effective, and sustainable measures to adopt. A3 techno Crafts is a system integrator providing different technical solutions to water management problems. Detailed research and expert technologists of A3 Techno Crafts assist you in the safe and smooth adaptation of conservative measures. Their tertiary wastewater treatment solutions include membrane systems, resin-based systems, and flocculation and sedimentation systems. In the membrane filtration system, membranes are used to remove harmful bacteria and viruses. In a resin system, ion-exchange resins are used for decontamination, purification, and separation. Chemical reactions are used to floc particles together helping them sediment fast in the flocculation and sedimentation system. Wastewater from different sources such as laundry, industrial effluents, hotels, hospitals, and sewage is treated with such processes and recycled for reuse. 

Integrating individual to industrial needs, A3 Techno Craft is leading the vision of water for all by providing sustainable technological solutions for water conservation. To know more, visit https://a3technocrafts.com/ and connect to us. 

Let us all stand for water conservation and do our bit to avoid the impending global water crisis. 

Purification and Recycling of Waste Water

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If there is no water, there will be absolutely no life on earth!

Fortunately, we have been blessed with plenty of water, the most precious gift given to us by God.

Nature has given us too much water that we had failed to appreciate or understand the real value of this precious gift.

Water is one of the most precious gifts ever created by God for humans to live on earth.

Unfortunately, we humans waste so much water in our daily life that sometimes Mother Nature would punish us by unleashing her fury in the form of natural disasters like floods, cloud burst, or even acute famine.

So let us ask ourselves a few vital questions. What is waste water? Why do we waste so much of water? How can we stop wasting and start saving water?

To answer the first question, waste water is the excess amount of water that we could have easily avoided wasting. For example, a normal person needs not more than twenty or thirty litres of water to take a normal bath. On the contrary, if he uses 40 or 50 litres of water in his shower, then he is using water twice more than what is really needed. This excess amount of water could have been saved.

So if one person is wasting about 30 litres of water on a daily basis, imagine a small family of three or four persons taking shower even once a day! They would have wasted at least 150 litres of water per day, if you do the math.

Taking shower is only one aspect of our life. What about the dozens of wasteful things we indulge in our life that one would die of heart attack, if he comes to realize the gravity of impending water crisis in our life. Observers predict that future wars will be fought over water, the “next oil”.

So how can A3 Techno Crafts help us save water and avoid the ‘next war?’

Well, purification and recycling of waste water is an expertise that A3 Techno Crafts have been grinding their nose for decades. Using latest state-of-the-art waste water purification technology, we can re-imagine a brave new world, where we all can lead a holistic life in perfect harmony with nature.

At A3, we are engaged in manufacturing and supply of a wide range of Water Treatment Plants, Sewage Treatment Plants, and Effluent Treatment Plants. Apart from these, we also offer complete turnkey solutions to our clients. Our entire range of plants and services are used in pharmaceutical, chemical, and food processing industry all over the world.

We have a team of professionals who have immense expertise in handling the complex treatment process. We have an excellent infrastructure to design, engineer, manufacture, carry out erection and commissioning of complete range of water treatment plant and systems to suit various requirements.

Our water purification technology is at par with international standards. And we are well-equipped to handle any challenges in the field of purification, recycling and conservation of water for the benefit of mankind. To send your query to us Click Here

Water is the Elixir of Life

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Though succinctly put, that Russian proverb says a lot about water. Doesn’t it?

Water is indispensable. And it is sacred and precious. Without water, there would be literally no ‘life’ on earth. That’s why water is called the Elixir of Life! Without water, we all would have died long ago.

Interestingly, human body consists of 70 per cent water and 30 per cent other substances. So it is paramountly important that the water we drink everyday should be clean and free from all kinds of harmful bacteria and other contaminants.

Unfortunately, that is not the case. The water we drink today is highly polluted and has become unfit for human consumption. It wouldn’t be an exaggeration if we were to say our body itself is polluted with contaminated water. The reason for this sorry state of affair is very clear.

Our insatiable greed for wealth and other luxuries in life have led to many disasters. Everyday tonnes of highly toxic industrial wastes, effluents, and other hazardous materials are released into rivers, lakes and other water bodies in our cities and towns.

The water we drink is contaminated; the air that we breath is highly polluted; and the fruits and vegetables that we eat are grown from indiscriminate use of harmful pesticides and chemicals. On top of that we are exposed to contaminated drinking water.

Unfortunately, this maxim that “water is the elixir of life” doesn’t hold water. Not anymore. Indiscriminate use of fossil fuels, and irresponsible release of hazardous industrial wastes and effluents into our rivers and water bodies have turned water – the Spring of Life – into a health hazard.

The idyllic days of living in harmony with Nature are long gone. Our simple and holistic way of life has irreversibly been taken over by our materialistic greed for modern luxuries of life.

OK! What does this have anything to do with A3 Techno Crafts Pvt Ltd? Yes, a lot! In fact, a lot more.

As a leader in water purification and management experts in treatment of industrial wastes and effluents, we offer a wide range of state-of-the-art technologies. From industrial waste management and treatment of solid wastes and effluents to purification and conservation of water, the God-given gift to humans and all other forms of life on Mother Earth. We are in mission mode: to restore our dwindling natural resources back to its pristine health.

Our decades-long expertise in water treatment and purification has enabled us to turn that dream into reality. To send your query to us Click Here