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Frontiers of Chemical Science and Engineering

ISSN 2095-0179

ISSN 2095-0187(Online)

CN 11-5981/TQ

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Front. Chem. Sci. Eng.    2016, Vol. 10 Issue (1) : 120-130    https://doi.org/10.1007/s11705-016-1559-1
RESEARCH ARTICLE
MILP synthesis of separation processes for waste oil-in-water emulsions treatment
Zorka N. Pintarič1,Gorazd P. Škof2,Zdravko Kravanja1,*()
1. Faculty of Chemistry and Chemical Engineering, University of Maribor, Smetanova ulica 17, SI-2000, Maribor, Slovenia
2. EKOLID, Ekološko svetovanje, Raziskave in razvoj, Ruška cesta 55, SI-2000, Maribor, Slovenia
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Abstract

This paper presents a novel synthesis method for designing integrated processes for oil-in-water (O/W) emulsions treatment. General superstructure involving alternative separation technologies is developed and modelled as a mixed integer linear programming (MILP) model for maximum annual profit. Separation processes in the superstructure are divided into three main sections of which the pretreatment and final treatment are limited to the selection of one alternative (or bypass) only, while within the intermediate section various combinations of different technologies in series can be selected. Integrated processes composed of selected separation techniques for given ranges of input chemical oxygen demand (COD) can be proposed by applying parametric analyses within the superstructure approach. This approach has been applied to an existing industrial case study for deriving optimal combinations of technologies for treating diverse oil-in-water emulsions within the range of input COD values between 1000 mg?L?1 and 145000 mg?L?1. The optimal solution represents a flexible and profitable process for reducing the COD values below maximal allowable limits for discharging effluent into surface water.
Keywords oil-in-water emulsion      chemical oxygen demand      superstructure      process synthesis      MILP     
Corresponding Author(s): Zdravko Kravanja   
Online First Date: 22 February 2016    Issue Date: 29 February 2016
 Cite this article:   
Zorka N. Pintarič,Gorazd P. Škof,Zdravko Kravanja. MILP synthesis of separation processes for waste oil-in-water emulsions treatment[J]. Front. Chem. Sci. Eng., 2016, 10(1): 120-130.
 URL:  
https://academic.hep.com.cn/fcse/EN/10.1007/s11705-016-1559-1
https://academic.hep.com.cn/fcse/EN/Y2016/V10/I1/120
Fig.1  General superstructure of an integrated separation process for O/W emulsions
Fig.2  The case-study superstructure of the O/W emulsions separation process
Technologies Inv/? rchem/(t×t?1) relec/(kWh×t?1) fsl/(t×t?1) com/(?×t?1) fCOD(%) cCODUP/(mg×L?1)
Chemical pretreatment (CP) – 0.022 1.7 0.15 – 30 n.a.a)
Mechanical pretreatment (MP) – – 5.5 0.10 – 15 n.a.
Chemical-mechanical pretreatment (CMP) – 0.022 7.2 0.15 – 45 n.a.
Skimming (ST) – – 0.5 0.05 – 10 n.a.
Evaporation (EV) 180000 – 50.0 0.08 8.00 90 80000
Electrocoagulation (EC) 50000 – 0.4 0.15 10.00 60 50000
Ultrafiltration (UF1) 100000 – 3.0 0.20 5.00 63 25000
Ultrafiltration (UF2) 80000 – 3.0 0.20 5.00 34 25000
Reverse osmosis (RO) 12000 – 3.0 0.15 5.00 70 20000
Active carbon adsorption (ACA) 10000 0.003 – 0.10 – 95 n.a.
Tab.1  Data for different treatment technologies
Unit Value
Income price of O/W emulsion (cO/W) ?×t?1 100
Mass flow rate of O/W emulsion (qmO/W) t×h?1 1.7
Annual operating time (ft) h×y?1 1800
Average price of chemicals (cchem) ?×t?1 337
Price of active coal (cchem) ?×t?1 1860
Electricity price (celec) ?×(kWh)?1 0.111
Sludge treatment cost (csltr) ?×t?1 93
Depreciation period (tD) y 10
Limit COD value for water effluent (cCODUP) mg×L?1 120
Tab.2  Economic and operating data
COD /(mg×L?1) Pretreatment Intermediate treatment Final treat.
CP MP CMP ST EV EC UF1 UF2 RO ACA
1000
2000
3000
5000
10000
20000
30000
40000
50000
60000
70000
80000
90000
100000
110000
120000
130000
140000
145000
Tab.3  Combination of processes for different input COD values
Fig.3  Profit and total annual cost vs. COD of input O/W emulsion
Fig.4  Investment vs. COD of input O/W emulsion
Fig.5  Costs vs. COD of input O/W emulsion
Fig.6  Block diagram of the proposed integrated process for O/W treatment
Abbreviations
MSingle-choice mixer after intermediate unit
MfSingle-choice mixer in final treatment section
MinSingle-choice mixer in intermediate treatment section
MpSingle-choice mixer in pretreatment section
MPMechanical pretreatment
SSingle-choice splitter before intermediate unit
SfSingle-choice splitter in final treatment section
SinSingle-choice splitter in intermediate treatment section
SpSingle-choice splitter in pretreatment section
Symbols
cchemPrice of chemical, ??t?1
cCODCOD value, mg?L?1
celecElectricity price, ??(kWh)?1
comOperation and maintenance cost, ??t?1
csltrSludge treatment cost, ??t?1
cO/WIncome price of oil-in-water emulsion, ??t?1
cTACTotal annual cost, ??y?1
EelecElectricity power, kW
fCODCOD removal efficiency, -
fslSludge-generation factor, -
ftAnnual operating time, h?y?1
InvInvestment, ?
PBProfit before tax, ??y?1
qmMass flow rate, t?h?1
rchemSpecific consumption of chemicals, t?t?1
relecSpecific consumption of electricity, kWh?t?1
tDDepreciation period, y
yBinary variable, -
Sets and indices
F, fset and index of final treatment units
I, iset and index of intermediate treatment units
IM, imset and index of inlet streams of mixer Mi
im′subset of streams to mixers Mi from splitter Sin
IS, isset and index of outlet streams of splitter Si
is′subset of streams from splitter Si to mixer Min
P, pset and index of pretreatment units
Super- and subscripts
chemChemicals
eEffluent
iInlet
sSludge
UPUpper bound
Tab.1  
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