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Zero Liquid Discharge: Crystallizer
Pretreatment
Discharge requirements for industrial wastewater
are becoming stricter. Many companies are moving
to zero liquid discharge (ZLD) systems. In this
example, water with high total dissolved solids
(TDS) is treated before it is sent to a crystallizer.
Crystallization is an evaporation process that
creates a pure water distillate that can be sent back
to the process. The remaining dissolved solids
form crystals that can be removed and sent for
disposal or used for something like road salt. The
pretreatment process protects the crystallizer and
the reverse osmosis filtration system by removing
material that could harm them. The pretreatment
includes three major steps: cold lime softening,
filtration, and sludge treatment.
Cold Lime Softening and Clarification
Softening is the removal of elements in the water
like calcium, magnesium, and silica that could
cause fouling or scaling of reverse osmosis or
crystallizer equipment. Softening begins with
chemical addition. Coagulant and polymer
improve the clarification process by encouraging
individual particles to form fast settling clusters
of particles. The Solids CONTACT CLARIFIERTM
Softener provides a reaction zone for the removal
of hardness. Lime and soda ash are added in the
reaction zone just before the feed water.
• Coagulant (when necessary) allows particles
to come together.
• Polymer helps individual particles form large
fast settling clusters.
• Lime is added to increase the pH to remove
calcium and magnesium hardness.
• Soda ash is added (when necessary) to
remove calcium hardness.
The WesTech Solids CONTACT CLARIFIER™
combines mixing, internal solids recirculation, gentle
flocculation and gravity sedimentation in a single
unit. The low shear impeller provides high volume
recirculation and low floc shear, while expending
less horsepower when compared to a conventional
unit. Superior clarification provided by the Solids
CONTACT CLARIFIER™ extends the life of the
ultrafiltration membranes and reduces the amount of
cleaning cycles, giving WesTech the most value from
their membrane ultrafiltration system.
Internally recirculated solids react with lime and
soda ash and form heavy faster settling particles.
The sludge is scraped to the center and removed for
dewatering.
Acid is added to the softened water to stop the
softening reaction. The pH is lowered to less than 8.
Usually hydrochloric acid is used because it doesn’t
add sulfates that could form gypsum scale in the
reverse osmosis and crystallization processes.
Filtration
Three stages of filtration are used; each provides
pretreatment to the next. The dual media filters
and the AltaFilter™ Ultrafiltration System remove
any remaining solid particles. The backwash water
is recycled back to the clarifier. Reverse osmosis
removes the dissolved solids from the water.
The treated water is sent back to the process. The
concentrated dissolved solids stream is sent to the
crystallizer.
Sludge Treatment
The underflow of the Solids CONTACT CLARIFIERTM
is pumped into a thickener. Polymer may be added
to improve settling and clarity. The thickener
increases the concentration of the sludge. The
overflow is sent back to the clarifier. The thickened
underflow is sent to a filter press or other type of
vacuum or pressure dewatering filter.
In the filter press the water is forced out of the
sludge under pressure. It may require additional
polymer to function properly. The cake is then
hauled off for disposal. The pressate and any wash
water get pumped to the reclaim water storage
sump with the backwash from the filtration systems
and then it is recycled back into the clarifier.