10000m³/day Textile Factory Sewage Treatment Project Case

1. Case Basic Information

1.1 Project Subject

• Provider: HELLA WATER, a professional supplier of high-performance water treatment product, specializes in large-scale industrial wastewater treatment solutions for the textile industry.
• Core Product: HLWW-1000T Sewage Treatment System (integrates mechanical filtration, air flotation, A2/O biochemical treatment, MBR membrane separation, and disinfection)
• Project Objective: Treat 10000m³/day of textile wastewater to meet recycling and discharge standards, achieving efficient removal of COD, BOD, chroma, and suspended solids.

1.2 Treatment Scale & Water Quality Parameters

Treatment Scale

• Daily Treatment Capacity: 10000 m³
• Hourly Treatment Capacity: 45 m³/h
• Continuous Operating Time: 24 hours/day
• Water Recovery Rate: 99%

Typical Textile Wastewater Inlet Quality

Parameter	Value
COD (Chemical Oxygen Demand)	800-1500 mg/L
BOD₅ (Biochemical Oxygen Demand)	350-600 mg/L
Suspended Solids (SS)	200-400 mg/L
Chroma	100-300 times
pH	6-9
Total Phosphorus (TP)	10-20 mg/L
Ammonium Nitrogen (NH₄⁺-N)	30-80 mg/L

Effluent Quality Standard (Recycling & Discharge)

Parameter	Value
COD	≤40 mg/L
BOD₅	≤10 mg/L
SS	≤5 mg/L
Chroma	≤10 times
pH	6.5-8.5
TP	≤1 mg/L
NH₄⁺-N	≤1.5 mg/L
Turbidity	≤5 NTU

1.3 Core Equipment Specifications

Equipment Module	Specifications	Quantity
Mechanical Bar Screen	Drive motor: 2HP; Rake chain + frame + guide rails; PLC control	1 set
Dissolved Air Flotation (DAF) Machine	Concrete structure; Dissolved air tank pressure: 0.4-0.6 MPa; Scraper system; PAC/PAM dosing device	1 set
A2/O Treatment Tank	Anaerobic + Anoxic + Oxic zones; Effective volume tailored to 10000m³/d capacity; Aeration system	1 set
MBR Membrane System	Lined enhanced PVDF hollow fiber membrane; Maximum tensile strength ≥300N; Anti-backwash stripping strength ≥5Bar	1 set
Secondary Sedimentation Tank	Gravity sedimentation; Sludge concentration: 8000-12000 mg/L; 304 stainless steel scraper	1 set
Disinfection System	Chlorine dioxide dosing device; Automatic control based on flow rate	1 set
MMF Filter Tank	Multi-media filtration; Supports deep purification for recycling	1 set
Sludge Dewatering Device	Stacked screw filter press; Sludge moisture content: 75-85%	1 set
Control System	PLC integrated control cabinet; Online monitoring (pH, flow rate, pressure, COD)	1 set
Sewage Lift Pump	Non-clogging spiral centrifugal pump; Open single-channel impeller; Power: 200kW × 10 units	10 units

1.4 Design Standards & Compliance

The system adheres to core national and industrial standards, including:

• GB 4287-2012: Integrated Wastewater Discharge Standard for Textile Industry
• GB 8978-1996: Integrated Wastewater Discharge Standard
• GB 50014-2006: Code for Design of Outdoor Drainage
• JB2932-1999: Technical Specifications for Water Treatment Equipment
• ISO, CE, CB, NSF Certifications
• National Invention Patents and Utility Model Patents for Core Technologies

1.5 Application Scenarios

• Large-scale textile and dyeing factory wastewater treatment
• Printing and dyeing industry high-chroma, high-organic matter wastewater purification
• Industrial wastewater recycling projects (production rinsing water reuse)
• Municipal-industrial integrated sewage treatment
• Water-scarce regions requiring high water recovery rates

2. Project Core Pain Points & Requirements

2.1 Industry Common Pain Points

1. High Pollution Load: Textile wastewater contains refractory dyes, auxiliaries, and high concentrations of organic matter, resulting in low BOD/COD ratio (0.45-0.5) and poor biodegradability.
2. Severe Chroma Pollution: Dyes in wastewater cause strong chroma (100-300 times), which is difficult to remove and affects water reuse.
3. Water Quality Fluctuations: Batch production leads to significant fluctuations in wastewater flow and pollutant concentration, impacting treatment stability.
4. Sludge Bulking Risk: High organic load and toxic substances easily cause sludge bulking in biochemical tanks, reducing treatment efficiency.
5. High Recycling Requirements: Water scarcity in textile production requires high recovery rates (≥95%), demanding deep purification technology.

2.2 Customer Core Requirements

• Efficient Purification: Remove ≥95% of COD, ≥90% of chroma, and ≥98% of BOD to meet recycling standards.
• Stable Operation: Adapt to water quality/quantity fluctuations and avoid sludge bulking or membrane fouling.
• High Water Recovery: Achieve 99% water reuse rate to save freshwater resources and reduce production costs.
• Low Operating Cost: Minimize energy consumption, chemical dosage, and sludge disposal costs.
• Intelligent Control: Realize automatic dosing, aeration adjustment, and fault alarm to reduce manual intervention.

3. Hella Water Customized Solutions

3.1 Process Design: Multi-Stage Purification + Recycling Integration

The solution adopts a “Mechanical Filtration → Regulation Tank → Dissolved Air Flotation → A2/O + MBR → Secondary Sedimentation → Disinfection → MMF Filtration → Recycling” integrated process:

1. Pretreatment Stage:
   • Mechanical Bar Screen: Intercepts suspended solids (fibers, debris) to prevent pump and membrane clogging; balances flow rate to avoid shock loads.
   • Regulation Tank: Adjusts water quality and quantity to ensure stable operation of subsequent processes.
   • Dissolved Air Flotation (DAF): Removes 90% of oil, emulsified substances, and refractory colloids; increases BOD/COD ratio to 0.55, improving biodegradability.
2. Biochemical & Membrane Treatment Stage:
   • A2/O Treatment Tank:
     • Anaerobic Zone: Phosphorus-accumulating organisms (PAOs) release phosphorus; organic matter decomposes into fatty acids (VFAs).
     • Anoxic Zone: Denitrifying bacteria convert nitrate/nitrite to nitrogen gas using organic carbon.
     • Oxic Zone: Nitrifying bacteria oxidize ammonia nitrogen to nitrate; PAOs absorb phosphorus, achieving nitrogen and phosphorus removal.
   • MBR Membrane System: Enhances solid-liquid separation; retains high-concentration microorganisms to improve pollutant removal efficiency; lined enhanced PVDF membrane resists fouling and backwashing damage.
3. Deep Purification & Recycling Stage:
   • Secondary Sedimentation Tank: Concentrates sludge (3000-5000 mg/L → 8000-12000 mg/L) and returns active sludge to biochemical tanks.
   • Disinfection: Chlorine dioxide dosing inactivates pathogenic microorganisms to meet recycling safety standards.
   • MMF Filter Tank: Deep filters effluent to remove residual suspended solids, ensuring recycling water quality.

3.2 Core Technical Advantages

Technical Highlight	Description
Enhanced MBR Membrane Technology	Lined PVDF membrane with high tensile strength and anti-backwash performance; no wire breakage or peeling; stable flux even after repeated immersion/drying.
Non-Clogging Pump Design	Spiral centrifugal impeller with open single-channel structure; lifts solid debris to prevent clogging, adapting to high-SS wastewater.
Efficient Chroma & COD Removal	DAF + A2/O + MBR synergy; refractory dyes and organics are degraded by microorganisms and intercepted by membranes, achieving ≥90% chroma removal.
Intelligent Process Control	PLC integrates online monitoring (pH, flow, pressure) and automatic adjustment of dosing/aeration; reduces labor intensity by 70%.
High Water Recovery	99% reuse rate; treated water is reused for production rinsing, saving 3.65 million m³ of freshwater annually.

3.3 Key Supporting Systems

• Pre treatment filtration system: Mechanical bar screen + DAF ensures inlet water quality for MBR membranes, extending service life.
• Chemical dosing system: Automatic PAC/PAM/chlorine dioxide dosing adjusts dosage based on water quality, optimizing chemical consumption.
• Sludge Treatment System: Stacked screw filter press dewaters sludge to 75-85% moisture content, reducing disposal volume and costs.

4. Project Effectiveness Verification

4.1 Pollutant Removal Efficiency

Pollutant	Inlet Concentration	Effluent Concentration	Removal Rate
COD	800-1500 mg/L	≤40 mg/L	≥97%
BOD₅	350-600 mg/L	≤10 mg/L	≥98%
SS	200-400 mg/L	≤5 mg/L	≥98.75%
Chroma	100-300 times	≤10 times	≥96.7%
TP	10-20 mg/L	≤1 mg/L	≥95%
NH₄⁺-N	30-80 mg/L	≤1.5 mg/L	≥97.5%

4.2 Operational Performance

• Stability: Continuous operation for 10,000 hours with stable effluent quality; adapts to ±30% flow fluctuations and ±25% COD concentration changes.
• Energy Efficiency: Total power consumption ≤0.8 kW·h/m³, lower than similar large-scale textile wastewater treatment systems (1.0-1.2 kW·h/m³).
• Membrane Service Life: MBR membrane service life ≥3 years with regular cleaning; no fouling or wire breakage reported.
• Maintenance Cycle: Routine maintenance once a week (screen cleaning, chemical replenishment); sludge cleaning every 10 days.

4.3 Economic & Environmental Benefits

• Economic Benefits: Annual freshwater savings ≈USD 730,000 (based on 0.2 USD/m³); reduced sewage discharge fees by 99%; chemical cost savings ≈USD 80,000/year.
• Environmental Benefits: Annual reduction of COD emission by ≈11,100 tons; chroma pollution elimination; sludge reduction by 60% compared to traditional processes.

5. Case Corresponding Product Quotation Description

5.1 Quotation Overview

Item	Description	Quantity	Unit Price (USD)	Total Amount (USD)
Core Treatment System	HLWW-1000T Sewage Treatment System (mechanical bar screen + DAF + A2/O + MBR + secondary sedimentation + disinfection + MMF filter)	10 sets	335,000	3,350,000
Auxiliary Equipment	Non-clogging sewage lift pumps (200kW), sludge dewatering device, PLC control system	1 set	Included in total	Included in total
Technical Documentation	Design drawings, operation manual, maintenance guide	1 set	Included in total	Included in total
Total EXW Quotation	–	–	–	3,350,000

5.2 Quotation Terms

Term Type	Details
Validity Period	30 working days from the date of quotation
Payment Terms	T/T: 40% deposit for production, 45% before shipping, 10% after installation, 5% after one-year warranty
Production & Delivery Cycle	15 days (production) + shipping time (varies by destination)
Warranty Period	12 months from the date of delivery (free repair/replacement for non-human damage under correct usage)
Installation & Maintenance	– Online support: Free (manual, video guidance, 7*24 online engineer) – On-site installation: Client bears visa, flight tickets, accommodation, and labor costs for engineers
Customization	Accepts design adjustments based on actual wastewater quality and site conditions (price and production time subject to change)

5.3 Additional Notes

• The quotation includes complete filter systems and control cabinets, with international transportation-standard packaging to prevent damage.
• The system is designed for 380V/3P/50Hz power supply; customized power supply can be provided upon request.
• Spare parts (MBR membranes, pump impellers, aeration plates) are provided at preferential prices for long-term supply.

6. Frequently Asked Questions (FAQ)

6.1 Installation & Commissioning

Q: What are the on-site installation requirements for the system?

A: The system requires a flat installation area of ≥1500 m² (for tanks and equipment) with load-bearing ≥5 tons/m². It needs access to 380V AC power supply (total installed capacity 2000kW) and stable wastewater inlet/drainage pipelines. We provide detailed design drawings for concrete tanks; on-site commissioning takes 7-10 days to complete system stabilization.

6.2 Maintenance & Upkeep

Q: How to maintain the MBR membrane and prevent fouling?

A: The MBR membrane requires regular cleaning: 1) Backwash with clean water daily; 2) Chemical cleaning with citric acid or sodium hypochlorite every 3 months; 3) Avoid oil and large solids entering the membrane tank (ensured by pre-treatment). The lined enhanced membrane design resists fouling, extending service life to ≥3 years.

Q: What is the routine maintenance frequency and key tasks?

A: Routine maintenance includes: 1) Daily: Check screen debris, DAF water level, and chemical dosing levels; 2) Weekly: Flush DAF pipelines, calibrate online instruments, and inspect pump operation; 3) Monthly: Inspect aeration system and sludge dewatering device; 4) Quarterly: Clean MBR membrane and replace filter elements.

6.3 Warranty & After-Sales

Q: What is covered under the 1-year warranty period?

A: Within the warranty period, we provide free repair or replacement for faults caused by design, manufacturing, or material defects, including core equipment (MBR membrane, pumps, control system), aeration devices, and dosing systems. Damage from improper operation, membrane fouling due to poor pre-treatment, or natural disasters is not covered.

Q: How to access after-sales support for large-scale systems?

A: We offer 7*24 online technical support via email and video calls. For on-site issues, engineers can be dispatched within 48 hours (additional fees apply for international travel). We also conduct quarterly return visits to monitor system performance and provide optimization suggestions.

6.4 Operational Cost

Q: What is the estimated monthly operating cost of the system?

A: For a 10000m³/day system, monthly operating costs include: 1) Electricity: ≈USD 216,000 (0.8 kW·h/m³ × 10000 m³/d × 30 d × 0.09 USD/kW·h); 2) Chemicals (PAC/PAM/chlorine dioxide): ≈USD 25,000; 3) Sludge disposal: ≈USD 18,000; 4) Labor: ≈USD 12,000. Total monthly cost: ≈USD 271,000.

6.5 Safety & Compliance

Q: Is the recycled water safe for textile production rinsing?

A: Yes. The treated water meets GB 4287-2012 and recycling standards, with no residual toxins or dyes. It is suitable for fabric rinsing, reducing production costs without affecting product quality. We provide third-party testing reports to verify water safety.

Q: How to handle system failures to avoid untreated wastewater discharge?

A: The system is equipped with emergency overflow pipelines and a backup pump system. In case of equipment failure, the PLC control system triggers real-time alarms and automatically switches to backup equipment. The regulation tank can store 4-6 hours of wastewater to prevent untreated discharge, minimizing environmental impact.

Would you like me to prepare a detailed MBR membrane maintenance manual that includes step-by-step cleaning procedures, chemical dosage tables, and troubleshooting guides for membrane fouling and system stability?