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<p>Zero Liquid Discharge (ZLD) represents an optimal model of a fully closed-loop system that enables the recovery of valuable resources. This study successfully implemented four stages of ZLD for both real industrial and synthetic complex wastewater, employing novel electrocoagulation (EC) and reverse osmosis (RO) processes. Each unit operation, including the water treatment process, was integrated into the ZLD framework. In the first stage, the EC process significantly reduced chemical oxygen demand (COD), total suspended solids (TSS), and total dissolved solids (TDS), with removal efficiencies ranging from 62.30% to 97.50%. It also effectively removed heavy metals, including copper (Cu), nickel (Ni), manganese (Mn), cadmium (Cd), and lead (Pb), achieving removal efficiencies between 91.70% and 100%. In the second stage, RO further enhanced the removal of TSS, TDS, and COD, with efficiencies ranging from 93.35% to 100%, and improved heavy metal removal, with efficiencies varying from 95.80% to 100%. The third stage, a thermal process, facilitated the recovery of valuable resources such as phosphate, nitrate, ammonium, and urea, with a recovery efficiency of 99.5%. In the fourth stage, additional thermal treatment led to the recovery of solid forms of ammonium, nitrate, and urea, achieving a recovery efficiency of up to 88.4%. The findings of this study demonstrate that the restructured ZLD system can achieve a fully closed-loop cycle with an overall efficiency of 98.7%.</p> Graphical Abstract <p></p>

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Zero Liquid Discharge Performance in Complex Fertilizer Industry Wastewater Treatment

  • 期刊论文

  • 发表日期：

    2025年11月5日

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  • Mahmoud Elsayed,
  • Abdelrahim M. Abdeldaim,
  • Mohamed F. Soliman,
  • Raouf Hassan,
  • Naira Meky

摘要

Zero Liquid Discharge (ZLD) represents an optimal model of a fully closed-loop system that enables the recovery of valuable resources. This study successfully implemented four stages of ZLD for both real industrial and synthetic complex wastewater, employing novel electrocoagulation (EC) and reverse osmosis (RO) processes. Each unit operation, including the water treatment process, was integrated into the ZLD framework. In the first stage, the EC process significantly reduced chemical oxygen demand (COD), total suspended solids (TSS), and total dissolved solids (TDS), with removal efficiencies ranging from 62.30% to 97.50%. It also effectively removed heavy metals, including copper (Cu), nickel (Ni), manganese (Mn), cadmium (Cd), and lead (Pb), achieving removal efficiencies between 91.70% and 100%. In the second stage, RO further enhanced the removal of TSS, TDS, and COD, with efficiencies ranging from 93.35% to 100%, and improved heavy metal removal, with efficiencies varying from 95.80% to 100%. The third stage, a thermal process, facilitated the recovery of valuable resources such as phosphate, nitrate, ammonium, and urea, with a recovery efficiency of 99.5%. In the fourth stage, additional thermal treatment led to the recovery of solid forms of ammonium, nitrate, and urea, achieving a recovery efficiency of up to 88.4%. The findings of this study demonstrate that the restructured ZLD system can achieve a fully closed-loop cycle with an overall efficiency of 98.7%.

Graphical Abstract