Optimal design of zero-water discharge rinsing systems

This paper is about zero liquid discharge in processes that use water for rinsing. Emphasis was given to those systems that contaminate process water with valuable process liquor and compounds. The approach involved the synthesis of optimal rinsing and recycling networks (RRN) that had a priori excluded water discharge. The total annualized costs of the RRN were minimized by the use of a mixed-integer nonlinear program (MINLP). This MINLP was based on a hyperstructure of the RRN and contained eight counterflow rinsing stages and three regenerator units: electrodialysis, reverse osmosis, and ion exchange columns. A "large-scale nickel plating process" case study showed that by means of zero-water discharge and optimized rinsing the total waste could be reduced by 90.4% at a revenue of $448,000/yr. Furthermore, with the optimized RRN, the rinsing performance can be improved significantly at a low-cost increase. In all the cases, the amount of valuable compounds reclaimed was above 99%.