12 - Treatment of Industrial Waste.pptx

TREATMENT OF
INDUSTRIAL WASTE
Unit IV
ASST. PROF. PRACHI DESAI, DON BOSCO COLLEGE OF ENGINEERING 1

BREWERIES, WINERIES,
DISTILLERIES
Unit IV

BREWERIES, WINERIES, DISTILLERIES
i. Introduction:
ii. While Breweries and Wineries produce beer and wine respectively, a large number of
products of varying origin are obtained in Distilleries.
iii. Products from distilleries includes industrial alcohols, rectified spirit, silent spirit, absolute
alcohol, beverage alcohol etc.
iv. But two things are common all the products:
v. All the products are obtained through the bio-chemical process of fermentation by yeast,
using carbohydrates as raw materials
vi. All the products contain ethyl alcohol in different proportions.

ORIGIN AND CHARACTERISTICS OF
BREWERIES WASTE
i. Making of beer essentially consists of two stages:
1. Preparation of malt from grains like Barley
2. Brewing (boiling and fermentation) the Barely.
Preparation of malt from grains like barley
i. In malt making, the barely grains are soaked in liquid to bleach out colour, and then made to
sprout (appear or begin to grow) under aerobic conditions.
ii. The grain malt is then dried and stored after screening the sprouts out.
iii. The malt from the malt house is then transported to the brewing section

BREWERIES WASTE
Brewing (boiling and fermentation) the Barely.
i. Medium of fermentation is prepared by making a mash of coarse grained malt
with hot water, and by transforming the starch to sugar by boiling with hops
(which are used to give a bitter flavor to beer.).
ii. The wort is then filtered and cooled.
iii. The filtered wort is then inoculated with a prepared suspension of yeast, which
ferments the sugar to alcohol.
iv. When the fermentation is complete the yeast and malt residue is filtered out
and finally the beer is carbonated before packing for sale.

BREWERIES WASTE
Item Malt house waste Brewery waste
pH 6.9—9.5 4.0—7.0
BOD 20—204 70—3000
Total solids 428—700 272—2724
Suspended solids 22—339 16—516
Total nitrogen 14—56 7—42
Note: All values except pH are expressed in mg/l.

BREWERIES WASTE
i. Contains a large amount of organic soluble solids indicated by a high B.O.D in the order of
400-800mg/l and low suspended solids.
ii. In the brewing plant, the major potential pollutant is the fermentation residue or the spent
grains.
iii. Wastes also originate in the preparation of yeast suspension, from washing of containers,
equipments and floors.
iv. Large volume of almost on polluted water also comes out as waste cooling water.
v. The waste from the brewing plant contains high-suspended solids and also a high B.O.D

DISTILLERIES WASTE:
The beverage alcohol industries utilize different grains, malted barley and molasses as raw
materials. Molasses (black strap type) are exclusively used as raw materials in the industrial
alcohol industry.
In beverage alcohol industry, the preparation of mash consists of:
Preparation of green malt
1. Preparation of cooked slurries of the grains
2. Mixing of the above two followed by pH, adjustment and nutrient (ammonium salts and
phosphates) supplementation.

DISTILLERIES WASTE:
On the other hand in molasses distilleries, the preparation of mash consists of:
1. Dilution by water to a sugar content of about 15%
2. pH adjustment to 4.0 - 4.5 to prohibit bacterial activities and
3. Nutrient addition (ammonium salts and phosphates) supplementation.
4. Yeast suspension is prepared with diluted molasses and then inoculated into the mash for
fermentation under controlled conditions.
5. The fermented liquor Containing alcohol is then sent to an overhead tank without separation
of the solid materials.
6. The same is then degasified, and then the alcohol is stripped leaving a spent wash.
7. The crude alcohol is then redistilled and stored in vats.

DISTILLERIES WASTE:
i. Malt house wastes also contribute towards pollution in beverage alcohol distilleries.
ii. B.O.D and solids contributing wastes
iii. Floor washes
iv. Waste cooling water
v. Wastes from the operations of yeast recovery or by-products recovery process also
contribute to the volume of these wastes

DISTILLERIES WASTE
Parameter Range Average Parameter Range Average
COD 15—176 77.7 Ammoniacal nitrogen 0.04—0.89 0.26
pH 3.5—5.7 4.2 Organic nitrogen 0.6—8.7 1.94
Temperature, °G 80—105 94 Sodium (Na2O) 0.13—2.51 1.04
Total solids 21—140 78.5
Potassium (K2O) Calcium
(CaO) 4.8—22.59 10.73
Suspended solids 1—13 5.1 Magnesium (MgO) 0.66—2.35 1.63
Dissolved solids 25—110 56.9 Phosphorus (P5+) 0.026—0.326 0.168
5-day BOD 7—95 35.7 Silicate (SiO2) — 1.51
Ash 16—40 28.9 Chloride (Cl—) 0.68—7.39 3.79
Volatile fatty
acids 0.7—5.5 2.18 Sulphate (SO42—) 1.56—6.6 4.36
Reducing sugars 14—45 26.5 Total iron (Fe2+) 0.001—0.12 0.69
Total nitrogen 0.6—8.9 1.79 Copper (Cu2+) 0.004—0.03 0.014
Zinc (Zn2+) 0.027—0.225
Note: All values except pH are expressed in mg/l.

WINERIES WASTE
The wineries utilize the fruit juices as the raw materials.
i. First operation in any winery is the pressing of fermentable juice from the fruits like grape
etc.
1. The waste from this operation includes the spent fruits or pomace, wastage of fermentable
juices and floor wastes etc.
ii. The second stage in any winery consists of fermentation of this juice.
iii. The wine attains its final form at this stage and requires only decantation, blending and
bottling for sale.
1. The waste from this stage comes from fermentation, decanting spillages, floor washes etc.

TREATMENT OF THE WASTES:
i. Brewery wastes being comparatively less strong can be treated by aerobic biological
treatment, after screening and neutralization.
ii. Biological treatment is accomplished by two- stage process for 90 - 94% B.O.D reductions.
iii. Yeast sludge from the distilleries which contains very high suspended solids and B.O.D and
is rich in proteins, carbo hydrates, vitamins may be treated separately for by product
recovery.
iv. Raw spent wash with low pH, high dissolved solids, high temperature, high sulphates, and
high B.O.D is not amenable to aerobic biological; treatment.
v. Two-stage biological methods of treatment consisting of an aerobic treatment have been
widely accepted as the only methods of treatment of the wastes from the distilleries

TREATMENT OF THE WASTES:
i. A single stage digester is usually adopted for the anaerobic treatment when land available is
limited.
ii. Anaerobic Lagooning is a low cost alternative to the digesters when land is available in
plenty.
Disadvantage:
i. Evolution of volatile gases and obnoxious Odour from the ponds.,
ii. Effluent of the digesters and the anaerobic lagoons still contain a high B.O.D, which
cannot be discharged into the receiving streams.
iii. These effluents can successfully be treated either in aerated lagoons, or in oxidation
ponds.

BY-PRODUCT RECOVERY
i. Yeast sludge from the distilleries contains the degradation product of the dead yeasts and
organic debris from the malt s like proteins, fats, vitamins and carbo-hydrates.
ii. On the other hand the spent wash contains the above nutrients plus unfermented sugars,
amino acids, ammonium phosphates etc.
iii. So two types of byproducts viz. the nutrient rich animal feed, and the potassium rich
fertilizers may be recovered in a distillery.
iv. The segregation of yeast sludge for processing for animal feed is practiced in some
distilleries, which in turn reduces the insoluble B.O.D load of the waste.

DAIRY PLANT UNIT IV

DAIRY WASTES
i. Dairies are centers where raw milk is processed, either for immediate consumption or
converted into dairy products such as whey, cheese, butter, dried milk powder and ice cream.
ii. These manufactured products may be supplied to other industries such as bakeries and candy
manufacture for use as raw material in their own products.
iii. Dairies handling milk are classified as receiving, bottling, condensing, dry milk powder
manufacturing, ice cream manufacturing, cheese making and butter making
iv. Waste water generated in a dairy contains contains putrescible organic constituents.
v. Almost all the organic constituents of dairy waste are easily biodegradable.
vi. Hence, the waste water is amenable to biological treatment—either aerobic or anaerobic, or
a combination of the two.

OPERATIONS IN A DAIRY
 Receiving: Raw milk is received from the fields. It is weighed and tested for its fat contents.
It is stored in refrigerated containers before further processing.
 Pasteurizing: This process consists of heating milk to 63°C for 30 minute and immediately
refrigerating.
 It kills all organisms, including the pathogenic organisms, which may have entered the milk
through diseased animals.
 Bottling: The pasteurized milk is filled in bottles, or polyethylene sachets for distribution to
the consumers. Bottling is invariably preceded by clarification and filtration.
 Condensing: Pasteurized milk is heated and evaporated under vacuum. Sugar is added to the
milk and the sweetened milk is filled in tin containers, packed and sent to the consumers.

 Dry milk manufacture:
i. Whole milk is preheated and centrifuged to separate the cream from the non-fat portion of
the milk.
ii. Cream is pasteurized and used as ice cream mix.
iii. Non-fat portion of the milk is further heated and evaporated under vacuum to a controlled
percentage of solids.
iv. The concentrated non-fat milk is then spray-dried.
 Casein making:
i. Curded or spoiled milk is treated with mineral acid to produce casein.
ii. The casein is then precipitated. Casein is used in the manufacture of plastics, paints, resins
and varnishes.

Cheese making:
i. Pasteurized milk is soured by adding a lactic
acid-producing bacterial culture.
ii. Mixture is allowed to ripen under controlled
temperature.
iii. Curd is then cut with knives and the excess
whey is allowed to drain.
iv. Removal of whey is done by pressing the curd
and the pressed blocks are stored under
controlled temperature and humidity for the
development of flavor and further ripening.
v. It is then packaged and stored at low
temperature.

Butter making:
i. Cream to be made into butter is pasteurized and
is ripened with bacterial culture.
ii. Churning at low temperature produces granules
from the butterfat in the cream.
iii. Buttermilk is then drained from the churn, butter
is washed, standardized for moisture and salt
content and is worked further till it agglomerates
into one mass.
iv. It is then packaged for distribution.

Flow Diagram in a Dairy Plant

ORIGIN AND CHARACTERISTICS OF DAIRY
WASTE
i. Average value of waste water generated ranges between 4 and 8 litres per liter of milk
processed.
ii. The bulk of water consumption goes towards cleaning of the equipment and floor washing.
iii. The average characteristics of dairy waste are:
1. 5 Day BOD 20°C 1200 mg/l,
2. COD 1800 mg/l
3. Suspended solids 600—800 mg/l
4. Oil and grease 200—900 mg/l.
iv. The ratio of COD:BOD is favourable for applying biological methods of treatment preceded
by some form of pretreatment such as flow equalization and oil and grease removal.

SOURCES OF DAIRY WASTE WATER
i. Manufacturing areas and the Equipment
ii. Bottle washing, can and tanker washing, floor washing
iii. Water softening plant (if one is provided), boiler house and refrigeration plant.
iv. Chemicals and detergents used in the washing operations are also present in the waste
waters.
v. If milk is supplied in glass bottles, solid waste generated consists of broken glass pieces and
aluminium foil (used to cover the mouth of the bottle).
vi. Polyethylene bags are used in place of glass bottles, torn bags are also present in the waste
water streams.

SOURCES OF DAIRY WASTE WATER
i. Washing of empty bottles, cans and tankers is done first with Hot water, then with a
chemical such as sodium metasilicate or a detergent and, finally, with steam.
ii. These are dried with Hot air before they are returned to the raw milk suppliers.
iii. Essential steps in reducing the pollution load in the dairy include:
1. Allowing the cans and tankers to be emptied completely by keeping them in inverted
position till almost all the milk is drained out.
2. Minimizing spillage and leakages in the bottling section.
3. Attending to leaks in pipes, valves and equipment promptly.
4. Observing good housekeeping practices.
5. Using minimum amount of water for cleaning operations.

TREATMENT OF DAIRY WASTE
i. Due to the intermittent nature of the waste discharge, it is desirable to provide, Equalization
tank with or without aeration before the same is sent for biological treatment.
ii. Grease trap is also necessary as a pretreatment to remove fat and other greasy substances
from the waste.
iii. Aeration for a day not only prevents the formation of lactic acid, but also reduces the BOD
by about 50%.
iv. Both high rates trickling filters and activated sludge plants can be employed very effectively
for a complete treatment of the dairy waste.
v. Low cost treatment methods like oxidation ditch, aerated lagoon, waste stabilization pond
etc. can be employed with simpler type of equipments and less maintenance.

SUGAR MILL UNIT IV

SUGAR MILL WASTE
Introduction
i. In Countries like India, Cuba and Jamaica the sugar is produced from sugar canes.
ii. Many other places beetroots are used as the raw materials for the sugar production.
iii. In India most of the sugar mills operate for about 4 to 8 months just after the harvesting of
the sugar canes
Sugarcane Beetroot

MANUFACTURING PROCESS
i. Sugar canes are cut into pieces and crushed in a series of rollers to extract the juice
ii. Juice is extracted from the sugar cane, leaving a fibrous residue called bagasse
iii. Milk of lime is then added to the juice and heated
iv. Coagulated juice is then clarified to remove the sludge.
v. Clarifier is further filtered through filter presses and the entire quantity of clarified juice is
treated by passing Sulphur dioxide gas through for removal of colour
vi. Clarified juice is then preheated and concentrated in evaporators and vacuum pans.
vii. Partially crystallized syrup from the vacuum pan is then transferred to the crystallizers,
where complete crystallization of sugar occurs.
viii. The massecuite is then centrifuged, to separate the sugar crystals from the mother liquor

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Figure 10.1 Cane sugar manufacturing flow diagram.

SOURCES OF WASTE WATER AND THE
CHARACTERISTICS OF THE WASTE
i. Mill house include the water used as splashes to extract maximum amount of juice, and
those used to cool the rolling bearings & contains high B.O.D due to the presence of sugar,
and oil from the machineries & large amount of suspended solids.
ii. The filter clothes, used for filtering the juice, need occasional cleaning.
iii. A large volume of water is required in the barometric condensers of the multiple effect
evaporators and vacuum pans.
iv. The water is usually partially or fully recirculated, after cooling through a spray pond.
v. Additional waste originates due to the leakages and spillages of juice, syrup and molasses in
different sections, and also due to the handling of molasses.

CHARACTERISTICS OF SUGAR MILL WASTE
Parameter Value
i. pH 4.6- 7.1
ii. C.O.D mg/l 600 - 4380
iii. B.O.D mg/l 300 - 2000
iv. Total Solids mg/l 870 - 3500
v. Total Volatile Solids mg/l 400 - 2200
vi. Total Suspended Solids mg/l 220 - 800
vii. Total Nitrogen mg/l 10 - 40
viii.C.O.D /B.O.D ratio 1.3 - 2.0

TREATMENT OF THE WASTES
i. Disposal of the effluent on land as irrigation water is practical in many sugar mills, but it is
associated with Odour problem.
ii. Aerobic treatment with conventional activated sludge process and trickling filter is not too
efficient, even at a low organic loading rate.
iii. A max B.O.D reduction of 51% is observed in a pilot plant study at Kanpur, where both
trickling filter and activated sludge process were tried.
iv. In view of the high cost of installation and supervision of the treatment units, and the
seasonal nature of the operation of this industry, it is generally observed that the
conventional aerobic treatment will not be economical in this country.
v. Anaerobic treatments of the effluent, using both digesters and lagoons, have been found to
be more effective and economical.

TREATMENT OF THE WASTES
i. A B.O.D reduction of about 70% was observed in a pilot plant study with an anaerobic
digester.
ii. The effluents of the anaerobic treatment units are found to contain sufficient nutrients
(nitrogen and phosphorous).
iii. As such further reduction of B.O.D can be accomplished in aerobic waste stabilization
ponds.
iv. Where sufficient land is available, a two stage biological treatment, with anaerobic lagoons
followed by aerobic waste stabilization ponds, is recommended for Indian conditions.
v. The mill effluent however is to be pretreated primarily in bar screens and grease trap.
vi. It is expected that the B.O.D reduction in the anaerobic process will be in the order of 60%,
while overall B.O.D reduction may be in the order of 90%

FERTILIZER INDUSTRY UNIT IV

FERTILIZER INDUSTRY
i. Fertilizers produced in India can be classified
broadly into two groups viz., nitrogen fertilizers,
and phosphatic fertilizer.
ii. Nitrogenous fertilizers: Urea, Ammonium
sulphate, Ammonium Nitrate, Ammonium chloride
iii. Phosphatic fertilizers: Super 63 phosphates
iv. Plants where complex fertilizers containing both
nitrogen and phosphates like Ammonium
phosphate and Ammonium sulphate phosphate are
produced.

WASTE WATER FROM FERTILIZER PLANT
A variety of wastes are discharged from the Fertilizer plant as water pollutants in the form of
1. Processing chemicals like Sulphuric acid
2. Process intermediate like Ammonium, Phosphoric and etc.
3. Final products like urea, Ammonium sulphate, Ammonium phosphate etc.
Wash water from the scrubbing towers may contain toxic substances like Arsenic,
Monoethanolamide, Potassium carbonate, Mixture of carbonic acid, hydrofluoric acid etc.
Both alkaline and acidic wastes are also expected from the boiler feed water treatment plant, the
wastes being generated during the regeneration of anion and cat ion exchanger units.
In addition to the above, oil bearing wastes from compressor houses of ammonia and urea plants,
some portion of the cooling water and the wash water from the scrubbing towers, for the
purification of gases, also come as waste.

FERTILIZER WASTE
Parameter Value
 pH 7.5to 9.5
 Total solids, mg/l 5400 mg/l
 Ammonia Nitrogen 700 mg/l
 Urea Nitrogen 600 mg/l
 Phosphate 75 mg/l
 Arsenic 1.5 mg/l
 Fluoride 15 mg/l

EFFECTS OF WASTES ON RECEIVING
STREAMS
i. All the components of the waste from the fertilizer plants induced adverse effects in the
stream.
ii. Acids and Alkalis can destroy the normal aquatic life in the stream.
iii. Arsenic, Fluorides and Ammonium salts are found to be toxic to the fishes.
iv. Presence of different types of salts renders the stream unfit for use as a source of drinking
water in the downstream side.
v. Nitrogen and other nutrient content of the waste encourage growth of aquatic plants in the
stream

TREATMENT OF FERTILIZER WASTE WATER
i. Standard practice has been contain the water for reuse, allowing enough time for solids
sedimentation.
ii. Oil is removed in a gravity separator, Arsenic containing waste is segregated and after its
concentration the solid waste is disposed off in a safe place.
iii. Phosphate and fluoride bearing wastes are also segregated and chemically coagulated by
lime; clarified effluent which still contains some amount of phosphate and fluoride is diluted
by mixing with other wastes.
iv. Ammonia from effluent is removed by gas scrubbing and gas cleaning operations.

PULP AND PAPER MILL
WASTE
UNIT IV

PULP AND PAPER MILL WASTE
The paper mills use the 'pulp' as the raw
material
JUTE BAMBOO
WOOD RICE OR WHEAT STRAW
SUGARCANE BAGGASE

MANUFACTURING OF PAPER
The Process of manufacturing of paper may be divided into
two phases - Pulp making and Final product of paper.
PULP MAKING - MECHANICAL
The bark is mechanically or hydraulically removed from
wood before it is reduced to chips.
Mechanically prepared (ground wood) pulp is made.
Pulp is low-grade , usually highly colored, and contains
relatively short fibers, it is mainly used to manufacture non
durable paper products such as newspaper.

i. Chemically prepared pulps are made by the Soda, Kraft or Sulfite process.
ii. Wood is prepared, as in the making of ground wood, by reduction to chips and screening to
remove dust.
iii. Pulping - process in which wood or other cellulosic raw materials are digested with
chemicals under high temperature and pressure so that cellulosic fibers of wood are relieved
from its binders such as lignin, resin etc.
iv. The chemical processes differ from one another only in the chemical used to digest the
chips.
v. Kraft process - Treatment of wood chips with a hot mixture of water, sodium hydroxide
(NaOH), and sodium sulfide (Na2S) that breaks the bonds that link lignin, hemicellulose,
and cellulose.

 The black liquor of the Kraft process is concentrated by evaporation, and then incinerated
with the addition of sodium sulphate.
 The resulting liquid is known as green liquor. Lime is added to this liquor, resulting in the
formation of white liquor.
 The lignin and non cellulosic materials are dissolved, leaving a stronger fiber for paper
formation.
 After digestion, the drained pulp is then washed.
 These wash waters may then be wasted, reused or sent through recovery operations while
the washed pulp is passed through some type of refining machine to remove knots and other
non disintegrated matter.

 A cylindrical screen, called a Decker, revolving
across the path of the pulp partially dewaters it,
after which it is passed to bleach tanks, where it is
mixed in a warm, dilute solution of calcium
hypochlorite or hydrogen peroxide.
 The dried, bleached pulp is then ready for sale or
delivery to the paper mill.
 Bleaching (3 stages) -Chlorine, Caustic and
Hypochlorite are used in successive stages.
 Waste waters from first and last stages are light
yellow in colour, while that from caustic highly
colored.

PAPER MILL
 Pulp mixture is disintegrated and mixed in a Beater.
 The Beater is essentially an oblong tank equipped
with a rotating cylinder, to which are attached dull
knives to break up the knotted or bunched fibers
and cause a through mixing of the entire contents of
the tank.
 Various fillers like alum, talc, dyes are added to
improve the quality of the final paper product, and
sizing to fill the pores of the paper.

PAPER MILL
 After beating, the pulp is refined in a Jordan
 Machine that consists of a stationary hollow cone
with projecting knives on its interior surface, fitted
over a rapidly rotating adjustable cone having
similar knives on its outside surface.
 This machine cuts the fibers to the final size
desired.
 Finally the pulp is screened to remove lumps or
slime spots, which would lower the quality of the
final paper.

 Pulp is evenly distributed from a head box over a
travelling belt of fine wire screening known as four
drive-in weir and carried to rolls .
 Screen roll to eliminate inequalities at the end of the
wire.
 Suction roll to draw out more water
 Press & Drying rolls to rid of the paper of most of the
remaining water
 Finishing rolls which produce the final shape of the
paper.

CHARACTERISTICS OF PULP AND PAPER
MILL WASTES
i. Volume depends mainly on the manufacturing procedure, and the water economy adopted in
the plant.
ii. Well operated and well managed produces a waste volume in the range of 225 to 320 m3 per
tone of paper manufactured.
iii. The mills manufacturing special quality of paper produce larger amount of water for
washing and bleaching.
iv. Like the volume of waste, the chemical composition of the waste will also depend on the
size of the plant, manufacturing process.
v. The pulp and paper mill wastes are characterized by very strong colour, high BOD , high
suspended solids and high COD/BOD ratio

THE EFFECT OF WASTES ON RECEIVING
WATER COURSES OR SEWERS:
i. Crude pulp and paper mill wastes, or insufficiently treated wastes cause very serious
pollution problems when discharged into the streams.
ii. The fine fibers often clog the water intake screens in the downstream side.
iii. A toxic effect may also be induced upon the flora and fauna of the stream due to sulfites and
phenols in the waste.
iv. The bottom deposit of Organic materials near the point of the discharge of the waste in a
stream undergo slow decomposition and may lead to the dissolved oxygen depletion
followed by the creation of anaerobic condition and destruction of the aquatic life.

TREATMENT OF THE WASTE
 Recovery: The fibers in the white water from the paper mills are recovered either by
sedimentation or by floatation using dissolved air in the tank.
 Chemical treatment for colour removal: Massive lime treatment capable of removing 90% of
colour and 40 to 60% of BOD from the waste.
 Activated carbon for colour removal: Acidic activated carbon can remove 94% colour from
the pulp mill waste.
 Mechanically cleaned circular clarifiers: 70-80% removal of the suspended solids, 95 to
99% removal of settable solids, BOD reduction is 25-40% only

TREATMENT OF THE WASTE
 Biological treatment of the waste: If sufficient area is available, the waste stabilization ponds
offer the cheapest means for treatment. A minimum of 85% removal of BOD is found to be
achievable.
 Aerated lagoons are the improved forms of the stabilization ponds.
 Activated sludge process is the most satisfactory and sophisticated system for the effluent
treatment.
 Trickling filter has got a limited use in the treatment of the pulp and paper mill effluent, due
to the greater chances of clogging of the media with fibrous material.
 Lagooning: In small mills, where the black liquor is not treated separately for the chemical
recovery, the strong black liquor must be segregated from the other wastes and stored in a
lagoon

PHARMACEUTICAL
INDUSTRY
UNIT IV

PHARMACEUTICAL INDUSTRY
Products of this industry may be classified as:
1. Chemical—antihistamines or hypnotics
2. Antibiotics—narrow spectrum or broad spectrum
3. Biologicals—vaccines or sera
4. Animal—hormones or extracts
5. Vegetable—fluid extracts
Forms - Tablets, pills, capsules, elixirs, extracts, tinctures, emulsions, suspensions, solutions,
lotions, syrups, mixtures, sprays, ointments, etc.
All the units have a ‘filling and packing' section, which produces a large amount of solid wastes
such as paper cartons, bottles, ampoules, rubber stoppers.
A unit having Quality Control laboratory has usually an animal house attached to it. Dead animals
and other solid wastes from this section need to be handled carefully and disposed of effectively.

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Figure 12.1 Penicillin manufacturing flow diagram.

CHARACTERISTICS OF PHARMACEUTICAL
WASTE
i. Colour Colourless
ii. Odour Fruity
iii. pH value 6.3
iv. BOD 1490
v. Albuminoid nitrogen 13
vi. Organic nitrogen 18
vii. Phosphates 72
viii. Sulphates 50
ix. Chlorides 90
x. Total solids 1900
xi. Suspended solids 420
xii. Volatile solids 880
Note: All values except pH are expressed in
mg/l.

i. Pharmaceutical industry produces medicines both by fermentation and by organic synthesis.
ii. Fermentation process produce vitamins , antibiotics, organic acids, enzymes, etc.
iii. Antibiotics and vitamins are synthesized by fungi or bacteria in large stirred tanks.
iv. Raw materials such as corn steep liquor, distiller's soluble, soyabean meal, fish or whole
soluble are used to provide nitrogen and growth factors
v. Energy is supplied by various sugars and starch.
vi. Manufacturing operations - Seed production, fermentation, Production of the desired
metabolite, filtration of the biomass, pH adjustment, removal of colour from the fermented
broth, extraction of the end products with solvents or on suitable resin columns, evaporation,
filtration and drying.

i. Synthetic drugs manufacturing plants produce effluents which can be classified as:
• Highly acidic, with pH less than or equal to 1.0
• Combined waste waters from all manufacturing blocks
• Floor washings from all blocks
• Sewage from the toilet blocks
ii. Effluents contain varying concentrations of heavy metals such as copper, chromium, zinc,
nickel and mercury.
iii. Synthetic drugs plants use a number of organic and inorganic chemicals and produce a
variety of drugs in different sections of the plant.
iv. The volume and composition of liquid wastes vary from one plant to another and one
product to another.

TREATMENT OF WASTE WATER
i. Physical, chemical and biological or a combination of the three.
ii. Recover solvents from the waste water and separation of mycelium.
1. Recovered solvents can be reused
2. Mycelium is used as chicken feed, since it contains essential growth factors.
iii. Treatment Process - Screening, grit removal, oil and grease removal (optional), Equalization,
adjusting pH between 7.0 and 8.0, Two-stage trickling filtration and Final clarification.
iv. Chlorination and sand filtration of the effluent from trickling filter can give up to 99.3%
BOD reduction
v. Activated sludge process and its modifications have been effectively used in treating
pharmaceutical waste water

PETROCHEMICAL
INDUSTRY
UNIT IV

PETROCHEMICALS INDUSTRY
i. Chemical derived from petroleum or natural gas are called Petrochemicals.
ii. Used for the production of solvents, detergent, synthetic resin and rubber, synthetic fibre and
pesticide, fertilizer and other chemical.
iii. Primary processes consist of combustion, cracking, catalytic, oxidation, pyrolysis, etc.
iv. Secondary processes include chemical reaction, recovery, purification, condensation,
scrubbing, recycling, distillation.
v. Quality characteristics of the waste water depend on the specific petrochemical being
produced.
vi. End product from these operations are ethylene, methanol, acetaldehyde, ethylene oxide,
acetic acid, ethylene glycol, polyethylene, propylene, butadiene, styrene, acrylonitrile,
butanol and caprolactam.

CHARACTERISTICS OF WASTE WATER
Source of waste water in a petrochemical complex are
 Direct discharge from production plant
 Cooling and Steam Raising system
 Sewage from Canteen and Toilet
 Contaminated discharge from production areas
 Miscellaneous discharge from spill.
 Include trace or large concentrate of raw material, all intermediate product, all final product,
coproduct, byproduct, auxiliary or process chemical used during manufacturing process.
 For overall pollution control, use the familiar parameter such as BOD, COD, Colour, Odour,
Toxicity, Foaming tendency , oil and grease.

TYPICAL CHARACTERISTICS OF
PETROCHEMICAL INDUSTRY EFFLUENTS.
Parameter A B G D E F F
Alkalinity 4060 36& 164 — — — —
BOD 1950 345 225 1950 16,800 16,700 170
Chlorides 430—800 1980 825 800 96,300 1,44,000 800
COD 7970 — 855 610 1972 21,700 27,500 2000 8540
Oils 547 73 — 547 — — 45
pH 9.4—9.8 9.2 7.5 — — — —
Phenols — 160 17 10—50 — — 400
Sulphates 655 280 — 655 — — —

TYPICAL CHARACTERISTICS OF
PETROCHEMICAL INDUSTRY EFFLUENTS.
Parameter A B G D E F F
Suspended Solids 27—60 121 110 60 700 348 Negligible
Total Solids 2191— 3770 2810 3029 172467 167221 3000
Notes: All values except pH are in mg/l
A: Mixed chemicals, including ethylene oxide, propylene oxide, glycols, amines and ethers.
B: Refinery, detergent alkylate.
C: Refinery, butadiene, butyl rubber.
D: Mixed organics.
E: 2,4,5, trichlorophenol.
F: 2,4 dichlorophenol.
E: Nylon. ASST. PROF. PRACHI DESAI, DON BOSCO COLLEGE OF ENGINEERING 65

TREATMENT OF PETROCHEMICAL WASTE
i. Oil-water separation, pH correction, Stripping for ammonia and Hydrogen Sulphide, Settling or
flotation is necessary before subjecting the waste water to biological treatment.
ii. Large balancing tank are strongly recommended to absorb wide fluctuation in quality and to
dilute toxic substance in the waste water.
iii. Activated sludge using extended aeration ic commonly used.
iv. Powdered activated carbon with activated sludge, improve efficiency of the process by adsorbing
organic not amenable to biodegradation.
v. High rate filter is designed to remove 70% organic load, followed by conventional activated
sludge process to achieve satisfactory quality of the treated effluent.
vi. Aerated lagoon are used as intermediate treatment step, followed by waste stabilization pond.
vii. Anaerobic treatment has been successful for treating low-strength waste.

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