1. 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

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

3. 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: )

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

5. 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)

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

7. 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

8. 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

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

10. 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

11. 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 equal 13.8 Mpa (140 kg/cm2).

12. 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 equal 240 kg/m3.

13. 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

14. 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

15. 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

16. 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

17. 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

18. Reusing wastewater (cont’d)
● Water Absorption: must not exceed the 8% maximum percentage specified in E.S.S
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

19. 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

20. 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

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

22. (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)

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

24. Questions?