I.

Design Project

Introduction

This report presents a detailed design and cost analysis of a water treatment system tailored for

the efficient removal of NAOH and hydrogen peroxide effluents. The system comprises four

essential units: two mechanical filters, a heater, a chemical filter, and a reverse osmosis unit,

each designed with a flow rate of 300 L. The objective is to provide a comprehensive solution

that ensures the removal of contaminants, meeting both environmental regulations and

sustainability standards. The report encompasses the design specifications, cost estimates, and

considerations for each unit, aiming to contribute to the development of environmentally

responsible water treatment systems.

The introduction outlines the need for a specialized water treatment system to address the

challenges posed by effluents containing NAOH and hydrogen peroxide. It highlights the

significance of designing a system that not only meets regulatory requirements but also

emphasizes sustainable practices in water management.

Design Specifications

This section delves into the specific design parameters for each unit, including the mechanical

filters, heater, chemical filter, and reverse osmosis unit. The chosen flow rate of 300 L is justified

based on the anticipated effluent volume and industry standards. Detailed schematics and

operational principles for each unit are presented to provide a clear understanding of the design.
 Figure 1: 3D Design of the Filtration System

1. Mechanical Filters:

The mechanical filters play a crucial role in removing particulate matter and larger impurities

from the effluent stream. This section discusses the design considerations, filter media selection,

and sizing calculations. It also outlines the maintenance protocols and expected efficiency of the

mechanical filters.
Design of Mechanical Filter for Solid Filtration:

Design Parameters and Assumptions:

Flow rate (Q): 300 L/day

Particle size: 2mm (sand particles)

Filtration efficiency: 100 %

Operating time: 24 hours/day

Filtration rate (v): 10 m/h (common value for solid filtration)

Calculate Filtration Area (A):

Q
A= (i)
v∗T ¿

Where:

A is the filtration area (m²),

Q is the flow rate (m³/day),

v is the filtration rate (m/h),

t is the operating time (h).

Area = (0.3)/(10*24)

Area = 0.00125 m2
Filter Bed Depth (h):

Q
h= (ii)
A∗t ¿

h = (0.3/ (0.00125*24)

h = 10 mm

Filter Media:

Filter media for solid filtration includes silica sand. The effective size (d10) of the sand should

be smaller than the particle size to ensure effective filtration.

Filter Bed Cross-Sectional Area (A'):

A
A '= (ii i)
Porosity ¿

Home based solid effluent has a porosity of 0.4:

A’ = (0.00125/0..4)

A’ = 0.003125 m2

Filter Bed Diameter (D):

4∗A '
D=√ (iii)
3.142¿
D = (4*0.003125)/3.142

D = 0.063 m

Summary of Mechanical Filter Design:

Filtration Area A: 0.00125 m²

Filter Bed Depth h: 10 mm

Filter Media: Silica sand

Filter Bed Cross-Sectional Area A: 0.003125 m²

Filter Bed Diameter D: 0.063 m

2. Heater:

The heater unit is essential for maintaining optimal operating temperatures, ensuring the

effectiveness of subsequent treatment processes. Design parameters, such as heating capacity,

energy efficiency, and safety features, are thoroughly discussed in this section.

Design of Heater (Burner heater):

Parameters and Assumptions:

Flow rate (Q): 300 L/h

Inlet water temperature (T1): Assume 15°C

Desired outlet water temperature (T2): Assume 40°C

Specific heat of water (Cp): 4.186 kJ/kg C

Efficiency of the burner (η): Assume 80%

Burner fuel type: Natural gas

Heat Transfer Requirements:

Q=m∗Cp∗(T 2−T 1)¿ (iv)

Where:

Q is the heat transfer rate (kJ/h),

m is the mass flow rate of water (kg/h),

Cp is the specific heat of water (kJ/kg°C),

T2 and T1 are the outlet and inlet temperatures, respectively.

Flow rate from Q (L/h) to m (kg/h) we can write equation (iv) as:

Q
m= (iv)
Cp∗(T 2−T 1)¿

m = (300)/(4.184)*(40-15)

m = 4.78 kg/h

Burner Input Power:

The burner input power Pin can be calculated using the efficiency formula.
 Q
P∈¿ (v )
n¿

Pin = {(4.78)*(4.184)*(40-15)}/0.8

Pin = 53.5 kW

Burner Type:

Burner with a capacity greater than 53.5 kW of natural gas fuel.

Summary:

Flow rate Q: 300 L/h

Inlet water temperature T1: 15°C

Outlet water temperature T2: 40°C

Mass flow rate m: 4.78 kg/h

Burner input power Pin : 53.5 kW

3. Chemical Filter:

The chemical filter is designed to neutralize and remove chemical contaminants from the

effluent. Details on the selection of appropriate chemical agents, dosing mechanisms, and

retention times are covered. The report also highlights the environmental impact of the chosen

chemical treatment.

Design of Chemical Neutralization Filter/Vessel:

Parameters and Assumptions:

Flow rate (Q): 300 L/h

Concentration of NaOH in the effluent: Assume 1% w/v

Concentration of HCl to be added: Assume 2N (normality)

Neutralization reaction: NaOH + HCl  NaCl + H2O

Reactor/Vessel material: Appropriate chemical-resistant material (e.g., polypropylene)

The Amount of NaOH in the Effluent:

Amount of NaOH =Concentration∗Flow rate¿ (vi)

Amount of NaOH} = 0.01*300

Amount of NaOH = 3 L/h

The Amount of HCl Needed for Neutralization:

Using the balanced chemical equation, we know that 1 mole of NaOH reacts with 1 mole of HCl.

The molarity (M) of HCl is equal to its normality (N) because it is a monoprotic acid.

Amount of HCl=Amount of NaOH / Normality ¿ (vii)

Amount of HCl = 3/2

Amount of HCl = 1.5 mol/h

The Volume of the Solution:

The molar volume of the solution can be calculated using the ideal gas law:

nRT
V= (vi ii)
P¿
Where:

V is the volume (m³),

n is the number of moles,

R is the ideal gas constant 8.314 J/(mol·K)

T is the temperature (AT 313 K)

P is the pressure (assumed to be atmospheric pressure, approximately 1 atm)

This volume represents the molar volume of the solution formed by the neutralization reaction.

V = (1.5*8.314*313)/1

V = 0.037 m3/h or 37 L/h

The Residence Time:

V
T= (ix)
Q¿

Residence time (T) = 37/300

T = 0.123 h

Volume of the Vessel:

This design estimates that a vessel with a volume of approximately 37 liters would be suitable

for neutralizing NaOH in the effluent by adding HCl, considering a residence time of 0.123

hours.
Summary:

Flow rate (\(Q\)): 300 L/h

Concentration of NaOH: 1% w/v

Concentration of HCl: 2N

Amount of NaOH in the effluent: 3 L/h

Amount of HCl needed for neutralization: 1.5 mol/h

Volume of a Vessel = 37 L

4. Reverse Osmosis Unit:

The reverse osmosis unit is a critical component for achieving a high level of purity in the treated

water. This section discusses membrane selection, pressure requirements, and system efficiency.

Consideration.

Single Membrane Design:

Design Parameters and Assumptions:

Flow rate (Q): 12.5 L/h

Desired rejection rate for H₂O₂: Assume 100%

Membrane surface area flux: Assume 15 L/ (m²·h·bar)

Membrane area per element: Assume 2 m² (for example, a small residential-scale membrane)
The Membrane Area:

Q
A= (x)
Flux∗Rejection Rate¿

A = 12.5/ (15*1)

A = 0.83 m2

The Number of Membrane Elements:

A
N= (x i)
M e mbrane per element ¿

A single membrane element with an area of 2 m² is used:

Number of membrane per element = 0.83/2

Number of membrane per element = 0.4

Round up to 1 membrane element for practical purposes.

Operating Pressure:

Assuming an operating pressure of 100 psi for this small-scale application.

Summary:

Flow rate Q: 12.5 L/h

Membrane area A: 0.88 m²

Number of membrane elements: 1

Operating pressure: 100 psi

Cost Analysis/Bill of Materials:

A comprehensive cost analysis is presented, including the capital costs for equipment,

installation, and ongoing operational expenses. The report discusses the economic feasibility of

the proposed water treatment system, taking into account long-term benefits and potential cost

savings.

Bill of Materials
Product: Date:
Assembly:
Item Part # Qty Name Material Source Lead Cost/
# Time Piece
1 1 Mechanical Plastic Guangzhou 1 week 150 SAR
Filter Begreat Smart
Life Co., Ltd
2 1 Burner 316 Stainless Guangzhou 5 days 1137 SAR
Steel Liancheng
Energy
Technology
Development
3 1 Vessel 316 Stainless Dalian Baoxiang 2 3000 SAR
Steel Packing weeks
Products Co.,
Ltd.
4 1 Membrane 316 Stainless JGP 2 200 SAR
Steel Corporation weeks
Saudi Arabia
Team Member: Prepared by:
Team Member: Checked by:
Team Member:
Team Member:
Team Member:

Product Links:

Mechanical https://www.alibaba.com/product-detail/3-Stage-5-Stage-7-
Filter Stage_1600655424809.html?
spm=a2700.galleryofferlist.p_offer.d_image.382ae918Rgjuyo&s=p
Heater https://www.alibaba.com/product-detail/E-series-China-top-manufacturer-
118_1600997408863.html?
spm=a2700.galleryofferlist.topad_classic.d_image.6f335e4eitGsnZ
Vessel https://www.alibaba.com/product-detail/Pressure-Vessel-Stainless-Steel-Ibc-
Tank_1600944133191.html?
spm=a2700.galleryofferlist.topad_classic.d_image.48f7493aP8UyRy
Membrane https://jgbsaudi.com/product/water-filtration-membranes/