The ZLD system utilizes a closed-loop water circulation process. Two separate loops, one for grinding and initial washing and another for post-washing, ensure thorough cleaning of plastic flakes. A key component of the system is a two-phase decanter that efficiently separates solids from liquids, allowing the treated water to be reused in the process. Advanced microfiltration further purifies the water, ensuring optimal cleaning performance.
The ZLD system has resulted in a dramatic reduction in fresh water consumption. Compared to traditional washing lines, the new system saves an estimated 5.5 million gallons of water per year. This substantial water conservation not only benefits the environment but also reduces operational costs.
The ZLD system also addresses the challenge of managing solid waste generated during the recycling process. The decanter removes microplastics, residual glue, label materials, and other contaminants, which are then disposed of responsibly.
Comparison of Water Usage without and with ZLD
| Operation of 2.5 ton/hour wash line withoutZLD | About 5.8 million gallons of fresh water and same amount of wastewater discharge in 1 year (that’s about 660 gal per hour fresh water converted to wastewater) |
| Operation of 2.5 ton/hour wash line with ZLD | Only 301,000 gallons of fresh makeup water needed per year to replace water loss in the wash line due to evaporation and flake adhesion. (that’s about 35 gal per hour).No wastewater is generated or discharged. |
Fresh Water Savings:
5,800,000 gallons per year water usage without ZLD, less 301,000 gallons per year ZLD make-up water = savings of 5,500,000 gallons of fresh water per year
Depending on your local water and sewer rates, savings of $100,000.00 +/- per year can be achieved.
