Case Studies from Egypt Reuse Wastewater Generated by the Paint and Textile Manufacturing Industries in the Manufacture of Cement Bricks and Tiles: Case Studies from Egypt by Dr. Robert W. Peters. Professor of Environmental Engineering University of Alabama at Birmingham, Birmingham, Alabama Eng.Mohamed Khaled Elsayed Mostafa Ph.D. Graduate Student Alabama Water resources Conference; Orange Beach, Alabama, September 5 - 7, 2012

Statement of scientific or technical problem Overview Statement of scientific or technical problem Introduction Primary objective of the research Reusing wastewater Conclusion

Statement of scientific or technical problem ● Poor quality of surface water in Egypt ►Some factors impacting this problem: 1- Discharge of industrial effluents into surface water body without prior treatment; 2- The use of old technologies and non-biodegradable substances in industrial processes; Mediterranean Sea (Source: www.inmagine.com, 2011)

Amount of wastewater produced from various industrial sectors Introduction Amount of wastewater produced from various industrial sectors (Source: National Research Centre, 2007 )

The loads of the most common contaminants contained within sewage Introduction The loads of the most common contaminants contained within sewage (Source: National Research Centre, 2007)

Primary objective of the research Paint industry ● Study potential reuse of wastewater generated by the paint and textile manufacturing industries. Textile industry

Total Dissolved Solids (TDS) Reusing wastewater Analysis of a typical paint wastewater sample Parameter Results (ppm) Cadmium (Cd) < 0.01 Magnesium (Mg) 5.0 Cobalt (Co) 0.03 Sodium (Na) 25.6 Nickel (Ni) Potassium (K) 0.3 Lead (Pb) Chlorine (Cl) 22.5 Iron (Fe) 0.01 Total Dissolved Solids (TDS) 4,576 Zinc (Zn) 0.05 PH (unitless) 9.58 Manganese (Mn) 0.04 Phosphor (p) 0.56 Copper (Cu) 0.07 Calcium (Ca) 11.5 Nitrogen (N) 29.4

Reusing wastewater (cont’d) Analysis of a typical dye wastewater sample Parameter Results (mg/l) Total Dissolved Solids (TDS) 18,165 Chlorine (Cl) 13,270 Total Suspended Solids (TSS) 1,572 Oil and grease 37.6 Chemical Oxygen Demand (COD) 943.0 Total Phosphate 5.2 Biological Oxygen Demand (BOD) 203.0 Organic nitrogen 21.0 PH (unitless) 10.12 Nitrate (NO3-) 5.0 Sulphur trioxide (SO3) 311.0 Nitrite (NO2-) 20 .0 Ammonia (NH3) 6.8

Reusing wastewater (cont’d) Statistical Market Forecast for Concrete Blocks and Tiles in Egypt (Source: Gobi International, 2009 )

Reusing wastewater (cont’d) Cement bricks Mix proportions of the cement bricks Brick: 25*12*6 cm Raw Material/Mixture No. A (Clean water) B (Paint WW) C (Dye WW) Coarse aggregate (m3) 0.9 Clean water (L) 288 N/A Wastewater (L) 225 Cement (kg) 400 Fine aggregate (m3) BVF (kg) 1.2

Reusing wastewater (cont’d) ● Compressive Strength: (Sample: 25*12*6 cm) Mix Sample Number Max. Stress (kg/cm²)   1 175 A (Clean water) 2 170 3 181 Average 172 B (Paint wastewater) 176 166 171 168 C (Dye wastewater) 174 180 ► Minimum compressive strength value specified in ASTM C 55-06 equal 13.8 Mpa (140 kg/cm2).

Reusing wastewater (cont’d) ● Water Absorption: The water absorption testing results Mix Sample Number Water absorption (kg/m³)   1 225 A (Clean water) 2 230 3 229 Average 228 212 B (Paint Wastewater) 215 216 214 206 C (Dye Wastewater) 208 209 ► Maximum water absorption value specified in ASTM C 55-06 equal 240 kg/m3.

Reusing wastewater (cont’d) ● Toxicity Characteristic Leaching Procedure (TCLP) Test: TCLP test results of the bricks Paint WW Dye WW Metals (mg/L) EPA limit (mg/L) Arsenic (As) ˂ 5.0 5.0 Cadmium (Cd) ˂ 0.05 1.0 Chromium Cr(total) 0.22 1.3 Copper (Cu) 0.007 2.8 15.0 Mercury (Hg) ˂ 0.001 0.06 0.2 Lead (Pb) ˂ 0.1 1.2 Zinc (Zn) ˂ 0.03 4.2 25.0 Iron (Fe) 3.5 Nickel (Ni) 0.079 2.5 7.0 Chloroform (CHCl3) 2.1 6.0 Chlorobenzene 20 100

Reusing wastewater (cont’d) ● Sulfide and Cyanides: Mix Sulfide, (mg/kg) Cyanides, (mg/kg) B (Paint wastewater) 1.52 ˂ 1.0 C (Dye wastewater) 4.50 EPA limit 500 250 ● Ignitability and Corrosivity: Mix Ignitability, °C (°F) Corrosivity, pH B (Paint wastewater) 100°C (212°F) 10.0 C (Dye wastewater) 110°C (230°F) 11.2 EPA limit Less than 60°C (140°F) (corrosive) pH < 2 or > 12.5

Reusing wastewater (cont’d) Cement tiles The mix proportions to produce 6 m2 tiles Tile: 30*30*2 cm Raw Material/Mixture No. A (Clean water) B (Paint WW) C (Dye WW) Coarse aggregate (kg) 120.0 Clean water (L) 15.0 N/A Wastewater (L) Cement (kg) 50.0 Fine aggregate (kg) 70.0 BVF (litter) 1.0

Reusing wastewater (cont’d) ● Compressive Strength: (Sample: 15*15*15 cm):Arduous service Compressive strength of the tiles after 28 days Mix Sample Number Max. Stress (kg/cm²)   1 701 A (Clean water) 2 736 3 671 Average 702 688 B (Paint WW) 680 685 684 700 C (Dye WW) 693 691 695

Reusing wastewater (cont’d) ● Bending Strength: (Sample: 30*10*2.0 cm): Arduous service Bending strength of the tiles after 28 days Mix Sample Number Max. Stress (kg/cm²)   1 88.7 A (Clean water) 2 89.2 3 93.85 Average 89.93 95.54 B (Paint WW) 95.7 93.48 94.61 95.4 C (Dye WW) 96.5 93.2 96.12

Reusing wastewater (cont’d) ● Water Absorption: must not exceed the 8% maximum percentage specified in E.S.S 269-2005. The water absorption testing results of the tiles Mix Sample Number %   1 4.44 A (Clean water) 2 4.57 3 4.7 Average 4.56 B (Paint WW) 4.55 4.22 4.41 C (Dye WW) 4.15 4.2 4.25

Reusing wastewater (cont’d) ● Toxicity Characteristic Leaching Procedure (TCLP) Test: TCLP test results of the tiles Paint WW Dye WW Metals Conc. (mg/l) EPA Limits (mg/l) Nickel (Ni) ˂ 0.05 0.6 7.0 Cadmium (Cd) 1.0 Copper (Cu) 0.005 0.1 15.0 Chromium Cr(total) 0.3 0.5 5.0 Lead (Pb) ˂ 0.1 ˂ 1.0 Zinc (Zn) 2.0 25.0

Reusing wastewater (cont’d) ● Abrasion resistance: (Sample 30*30*2 cm): Arduous service The abrasion testing results of the tiles Mix Sample Number Loss in thickness, mm   1 0.91 A (Clean water) 2 0.71 3 0.70 Average 0.75 0.93 B (Paint WW) 0.97 0.82 C (Dye WW) 0.79 0.84 0.81

Recommendation ● Construct a unit to produce the cement bricks and tiles near to the wastewater stream. Egg-laying machine Tile machine Concrete mixer

(Source: with permission from CMB Company, Egypt) Conclusion ● Reuse wastewater generated by the paint and textile manufacturing industries. The monthly volumes of wastewater going for treatment (wastewater from washing and cleaning the tanks) (Source: with permission from CMB Company, Egypt)

Conclusion (cont’d) Different shapes of cement bricks Different shapes of cement tiles

Questions?