There are many uses of water in industry and, in most cases, the used water also needs treatment to render it fit for re-use or disposal. Raw water entering an industrial plant often needs treatment to meet tight quality specifications to be of use in specific industrial processes. Industrial water treatment encompasses all these aspects which include

industrial wastewater treatment Industrial wastewater treatment describes the processes used for treating wastewater that is produced by industries as an undesirable by-product. After treatment, the treated industrial wastewater (or effluent) may be reused or released to a sa ...

boiler water Boiler water is liquid water within a boiler, or in associated piping, pumps and other equipment, that is intended for evaporation into steam. The term may also be applied to raw water intended for use in boilers, treated boiler feedwater, steam ...

treatment and

cooling water Cooling tower and water discharge of a nuclear power plant Water cooling is a method of heat removal from components and industrial equipment. Evaporative cooling using water is often more efficient than air cooling. Water is inexpensive and non ...

treatment.

Overview

Water treatment is used to optimize most water-based industrial processes, such as heating, cooling, processing, cleaning, and rinsing so that operating costs and risks are reduced. Poor water treatment lets water interact with the surfaces of pipes and vessels which contain it. Steam

boiler A boiler is a closed vessel in which fluid (generally water) is heated. The fluid does not necessarily boil. The heated or vaporized fluid exits the boiler for use in various processes or heating applications, including water heating, central h ...

s can scale up or corrode, and these deposits will mean more fuel is needed to heat the same amount of water.

Cooling tower A cooling tower is a device that rejects waste heat to the atmosphere through the cooling of a coolant stream, usually a water stream to a lower temperature. Cooling towers may either use the evaporation of water to remove process heat and ...

s can also scale up and corrode, but left untreated, the warm, dirty water they can contain will encourage bacteria to grow, and

Legionnaires' disease Legionnaires' disease is a form of atypical pneumonia caused by any species of ''Legionella'' bacteria, quite often '' Legionella pneumophila''. Signs and symptoms include cough, shortness of breath, high fever, muscle pains, and headaches. Naus ...

can be the fatal consequence. Water treatment is also used to improve the quality of water contacting the manufactured product (e.g., semiconductors) and/or can be part of the product (e.g., beverages, pharmaceuticals). In these instances, poor water treatment can cause defective products. In many cases, effluent water from one process can be suitable for reuse in another process if given suitable treatment. This can reduce costs by lowering charges for water consumption, reduce the costs of effluent disposal because of reduced volume, and lower energy costs due to the recovery of heat in recycled wastewater.

Objectives

Industrial water treatment seeks to manage four main problem areas:

scaling Scaling may refer to: Science and technology Mathematics and physics * Scaling (geometry), a linear transformation that enlarges or diminishes objects * Scale invariance, a feature of objects or laws that do not change if scales of length, energ ...

corrosion Corrosion is a natural process that converts a refined metal into a more chemically stable oxide. It is the gradual deterioration of materials (usually a metal) by chemical or electrochemical reaction with their environment. Corrosion engine ...

, microbiological activity and disposal of residual wastewater. Boilers do not have many problems with microbes as the high temperatures prevent their growth.

Scaling Scaling may refer to: Science and technology Mathematics and physics * Scaling (geometry), a linear transformation that enlarges or diminishes objects * Scale invariance, a feature of objects or laws that do not change if scales of length, energ ...

occurs when the chemistry and temperature conditions are such that the dissolved mineral salts in the water are caused to precipitate and form solid deposits. These can be mobile, like a fine silt, or can build up in layers on the metal surfaces of the systems. Scale is a problem because it insulates and heat exchange becomes less efficient as the scale thickens, which wastes energy. Scale also narrows pipe widths and therefore increases the energy used in pumping the water through the pipes.

Corrosion Corrosion is a natural process that converts a refined metal into a more chemically stable oxide. It is the gradual deterioration of materials (usually a metal) by chemical or electrochemical reaction with their environment. Corrosion engine ...

occurs when the parent metal oxidises (as iron rusts, for example) and gradually the integrity of the plant equipment is compromised. The corrosion products can cause similar problems to scale, but corrosion can also lead to leaks, which in a pressurised system can lead to catastrophic failures. Microbes can thrive in untreated cooling water, which is warm and sometimes full of organic nutrients as wet cooling towers are very efficient air scrubbers. Dust, flies, grass, fungal spores, and others collect in the water and create a sort of "microbial soup" if not treated with biocides. Many outbreaks of the deadly Legionnaires' Disease have been traced to unmanaged cooling towers, and the UK has had stringent Health & Safety guidelines concerning cooling tower operations for many years as have had governmental agencies in other countries. Certain processes like tanning and paper making use heavy metals such as Chrome for tanning. Although most is used up but some amount remains and gets carried away with water. The presence in drinking water is toxic when consumed so even the smallest amount must be removed.

Disposal of residual industrial wastewaters

Disposal of residual wastewaters from an industrial plant is a difficult and costly problem. Most petroleum refineries, chemical and petrochemical plants have onsite facilities to treat their wastewaters so that the pollutant concentrations in the treated wastewater comply with the local and/or national regulations regarding disposal of wastewaters into

sewage treatment Sewage treatment (or domestic wastewater treatment, municipal wastewater treatment) is a type of wastewater treatment which aims to remove contaminants from sewage to produce an effluent that is suitable for discharge to the surrounding envir ...

plants or into rivers, lakes or oceans.

Processes

Two of the main processes of industrial water treatment are ''boiler water treatment'' and ''cooling water treatment''. A large amount of proper water treatment can lead to the reaction of solids and bacteria within pipe work and boiler housing. Steam boilers can suffer from scale or

when left untreated. Scale deposits can lead to weak and dangerous machinery, while additional fuel is required to heat the same level of water because of the rise in thermal resistance. Poor quality dirty water can become a breeding ground for bacteria such as ''

Legionella ''Legionella'' is a genus of pathogenic gram-negative bacteria that includes the species '' L. pneumophila'', causing legionellosis (all illnesses caused by ''Legionella'') including a pneumonia-type illness called Legionnaires' disease and a mi ...

'' causing a risk to public health. Corrosion in low pressure boilers can be caused by dissolved oxygen, acidity and excessive alkalinity. Water treatment therefore should remove the dissolved oxygen and maintain the boiler water with the appropriate pH and alkalinity levels. Without effective water treatment, a cooling water system can suffer from scale formation, corrosion and fouling and may become a breeding ground for harmful bacteria. This reduces efficiency, shortens plant life and makes operations unreliable and unsafe.

Boiler water treatment

Boiler water treatment Boiler water is liquid water within a boiler, or in associated piping, pumps and other equipment, that is intended for evaporation into steam. The term may also be applied to raw water intended for use in boilers, treated boiler feedwater, steam ...

is a type of industrial water treatment focused on removal or chemical modification of substances potentially damaging to the boiler. Varying types of treatment are used at different locations to avoid scale,

, or

foaming Foams are materials formed by trapping pockets of gas in a liquid or solid. A bath sponge and the head on a glass of beer are examples of foams. In most foams, the volume of gas is large, with thin films of liquid or solid separating the r ...

. External treatment of raw water supplies intended for use within a boiler is focused on removal of impurities before they reach the boiler. Internal treatment within the boiler is focused on limiting the tendency of water to dissolve the boiler, and maintaining impurities in forms least likely to cause trouble before they can be removed from the boiler in boiler blowdown.

Cooling water treatment

Water cooling Cooling tower and water discharge of a nuclear power plant Water cooling is a method of heat removal from components and industrial equipment. Evaporative cooling using water is often more efficient than air cooling. Water is inexpensive and non ...

is a method of

heat In thermodynamics, heat is defined as the form of energy crossing the boundary of a thermodynamic system by virtue of a temperature difference across the boundary. A thermodynamic system does not ''contain'' heat. Nevertheless, the term is al ...

removal from components of machinery and industrial equipment.

Water Water (chemical formula ) is an inorganic, transparent, tasteless, odorless, and nearly colorless chemical substance, which is the main constituent of Earth's hydrosphere and the fluids of all known living organisms (in which it acts as a ...

may be a more efficient heat transfer fluid where

air cooling Air cooling is a method of dissipating heat. It works by expanding the surface area or increasing the flow of air over the object to be cooled, or both. An example of the former is to add cooling fins to the surface of the object, either by maki ...

is ineffective. In most occupied climates water offers the

thermal conductivity The thermal conductivity of a material is a measure of its ability to conduct heat. It is commonly denoted by k, \lambda, or \kappa. Heat transfer occurs at a lower rate in materials of low thermal conductivity than in materials of high thermal ...

advantages of a liquid with unusually high

specific heat capacity In thermodynamics, the specific heat capacity (symbol ) of a substance is the heat capacity of a sample of the substance divided by the mass of the sample, also sometimes referred to as massic heat capacity. Informally, it is the amount of heat t ...

and the option that of evaporative cooling. Low cost often allows rejection as waste after a single use, but recycling coolant loops may be pressurized to eliminate evaporative loss and offer greater portability and improved cleanliness. Unpressurized recycling coolant loops using evaporative cooling require a blowdown waste stream to remove impurities concentrated by evaporation. Disadvantages of water cooling systems include accelerated

and maintenance requirements to prevent heat transfer reductions from

biofouling Biofouling or biological fouling is the accumulation of microorganisms, plants, algae, or small animals where it is not wanted on surfaces such as ship and submarine hulls, devices such as water inlets, pipework, grates, ponds, and rivers that ...

or scale formation. Chemical additives to reduce these disadvantages may introduce toxicity to wastewater. Water cooling is commonly used for cooling

automobile A car or automobile is a motor vehicle with Wheel, wheels. Most definitions of ''cars'' say that they run primarily on roads, Car seat, seat one to eight people, have four wheels, and mainly transport private transport#Personal transport, pe ...

internal combustion engines An internal combustion engine (ICE or IC engine) is a heat engine in which the combustion of a fuel occurs with an oxidizer (usually air) in a combustion chamber that is an integral part of the working fluid flow circuit. In an internal combus ...

and large industrial facilities such as

nuclear Nuclear may refer to: Physics Relating to the nucleus of the atom: * Nuclear engineering *Nuclear physics *Nuclear power *Nuclear reactor *Nuclear weapon *Nuclear medicine *Radiation therapy *Nuclear warfare Mathematics *Nuclear space *Nuclear ...

and steam electric power plants,

hydroelectric Hydroelectricity, or hydroelectric power, is electricity generated from hydropower (water power). Hydropower supplies one sixth of the world's electricity, almost 4500 TWh in 2020, which is more than all other renewable sources combined and ...

generators,

petroleum refineries An oil refinery or petroleum refinery is an industrial process plant where petroleum (crude oil) is transformed and refined into useful products such as gasoline (petrol), diesel fuel, asphalt base, fuel oils, heating oil, kerosene, liquefie ...

and

chemical plants A chemical substance is a form of matter having constant chemical composition and characteristic properties. Some references add that chemical substance cannot be separated into its constituent elements by physical separation methods, i.e., wit ...

Technologies

Advancements in

water treatment Water treatment is any process that improves the Water quality, quality of water to make it appropriate for a specific end-use. The end use may be drinking water, drinking, industrial water supply, irrigation, river flow maintenance, water recrea ...

technology have affected all areas of industrial water treatment. Although mechanical filtration, such as

reverse osmosis Reverse osmosis (RO) is a water purification process that uses a partially permeable membrane to separate ions, unwanted molecules and larger particles from drinking water. In reverse osmosis, an applied pressure is used to overcome osmotic pre ...

, is widely employed to filter contaminants, other technologies including the use of ozone generators, wastewater evaporation,

electrodeionization Electrodeionization (EDI) is a water treatment technology that utilizes electricity, ion exchange membranes, and resin to deionize water and separate dissolved ions (impurities) from it. It differs from other water purification technologies in ...

and

bioremediation Bioremediation broadly refers to any process wherein a biological system (typically bacteria, microalgae, fungi, and plants), living or dead, is employed for removing environmental pollutants from air, water, soil, flue gasses, industrial effluent ...

are also able to address the challenges of industrial water treatment. Ozone treatment is a process in which ozone gas is injected into waste streams as a means to reduce or eliminate the need for water treatment chemicals or sanitizers that may be hazardous, including chlorine.

Chemical treatment

Chemical treatments utilizes the additive of chemicals to make industrial water suitable for use or discharge. These includes processes like chemical precipitation, chemical disinfection,

Advanced oxidation process Advanced oxidation processes (AOPs), in a broad sense, are a set of chemical treatment procedures designed to remove organic (and sometimes inorganic) materials in water and wastewater by oxidation through reactions with hydroxyl radicals (·OH) ...

(AOP), ion exchange, and chemical neutralization. AOPs are attractive in the treatment of hazardous wastewater due to its high oxidation potential and degradation performance. In AOPs, oxidants like

Fenton's reagent Fenton's reagent is a solution of hydrogen peroxide (H2O2) with ferrous iron (typically iron(II) sulfate, FeSO4) as a catalyst that is used to oxidize contaminants or waste waters as part of an advanced oxidation process. Fenton's reagent can be us ...

Ozone Ozone (), or trioxygen, is an inorganic molecule with the chemical formula . It is a pale blue gas with a distinctively pungent smell. It is an allotrope of oxygen that is much less stable than the diatomic allotrope , breaking down in the lo ...

Hydrogen peroxide Hydrogen peroxide is a chemical compound with the formula . In its pure form, it is a very pale blue liquid that is slightly more viscous than water. It is used as an oxidizer, bleaching agent, and antiseptic, usually as a dilute solution (3%� ...

are introduced in the wastewater to degrade harmful substances in industrial water for discharge.

Physical treatment

Physical treatment involves the separation of solids form industrial wastewater either through

Filtration Filtration is a physical separation process that separates solid matter and fluid from a mixture using a ''filter medium'' that has a complex structure through which only the fluid can pass. Solid particles that cannot pass through the filter ...

Dissolved air flotation Dissolved air flotation (DAF) is a water treatment process that clarifies wastewaters (or other waters) by the removal of suspended matter such as oil or solids. The removal is achieved by dissolving air in the water or wastewater under pressure an ...

. Filtration involves the use of

Membrane A membrane is a selective barrier; it allows some things to pass through but stops others. Such things may be molecules, ions, or other small particles. Membranes can be generally classified into synthetic membranes and biological membranes. B ...

or filters such as mechanical filters like sand filtration etc to achieve solid-liquid separation. Whereas for

, pressurized air is pumped into the wastewater. The pressurized air then forms small bubbles which adhere to the suspended matter causing them to float to the surface of the water where they can be removed by a skimming device or an overflow.

Biological treatment

Biological treatment is needed to treat wastewater containing biodegradable elements. It is commonly used in municipal and industrial wastewater management facilities and usually consists in adding common bacteria and other microbes, mostly environmentally friendly, to treat the water. It is a sustainable practice that has been successful for over a century.

Slow sand filters Slow sand filters are used in water purification for treating raw water to produce a potable product. They are typically deep, can be rectangular or cylindrical in cross section and are used primarily to treat surface water. The length and bre ...

use a biological process to purify raw water to produce potable water. They work by using a complex biological film that grows naturally on the surface of sand. This gelatinous biofilm called the hypogeal layer or

Schmutzdecke Schmutzdecke (German, "dirt cover" or dirty skin, sometimes wrongly spelled schmutzedecke) is a hypogeal biological layer formed on the surface of a slow sand filter. The schmutzdecke is the layer that provides the effective purification in potabl ...

is located in the upper few millimetres of the sand layer. The surface biofilm purifies the water as it flows through the layer, the underlying sand provides a support medium for the biological treatment layer. The Schmutzdecke consists of bacteria, fungi, protozoa, rotifera and a range of aquatic insect larvae. As the biofilm ages, more algae may develop and larger aquatic organisms including bryozoa, snails and Annelid worms may be present. As water passes through the hypogeal layer, particles of matter are trapped in the mucilaginous matrix and soluble organic material is adsorbed. The contaminants are metabolised by the bacteria, fungi and protozoa. Slow sand filters are typically 1–2 metres deep, and have a hydraulic loading rate of 0.2–0.4 cubic metres per square metre per hour. Filters lose their performance as the biofilm thickens and reduces the rate of flow. The filter is refurbished by removing the biofilm and a thin upper layer of sand. Water is decanted back into the filter and re-circulated to enable a new biofilm to develop. Alternatively wet harrowing involves stirring the sand and flushing the biolayer through for disposal.

Ultraviolet irradiation

Ultraviolet Ultraviolet (UV) is a form of electromagnetic radiation with wavelength from 10 nanometer, nm (with a corresponding frequency around 30 Hertz, PHz) to 400 nm (750 Hertz, THz), shorter than that of visible light, but longer than ...

(UV) disinfection technology has been a common water treatment technology in the past two decades due to its ability to provide disinfected water without the use of harmful chemicals. The UV-C portion represents wavelengths from 200 nm - 280 nm which is used for disinfection. UV-C photons penetrate cells and damage the nucleic acid, rendering them incapable of reproduction, or microbiologically inactive.

Process water treatment technology

Process water is water that is used in a variety of manufacturing operations, such as: coating and plating; rinsing and spraying; washing, etc. Municipal and ground water often contain dissolved minerals which make it unsuitable for these processes because it would affect product quality and/or increase manufacturing costs. A proper incoming water treatment system can remedy these issues and create the right water conditions for specific industrial processes.

References

{{Reflist Industrial processes Water treatment ja:下水処理場