Claims:I/We claim:
1. An automated system for treating waste water, comprising:
an electrocoagulation (EC) unit (102) that is connected to a collection tank (104) through a first flow line (106) for receiving waste water, wherein said electrocoagulation unit (102) comprises:
a nonconductive outer shell;
an electrode assembly that is placed inside said nonconductive outer shell comprising
a plurality of electrodes (406) that are arranged in parallel and being closely spaced in a vertical position between said plurality of electrodes (406), wherein said waste water flows between said plurality of electrodes (406) from a bottom of said electrode assembly to a top of said electrode assembly, wherein said plurality of electrodes comprises a plurality of anodes and a plurality of cathodes; and
a plurality of holders (408) that tightly holds said plurality of electrodes (406);
a first inlet valve (107) that is connected to said first flow line (106) feeds said waste water inside said electrocoagulation unit (102); and
a control unit that is electrically connected to said electrocoagulation unit (102), wherein said control unit is configured to
activate an electrocoagulation feed pump (108) to pump said waste water through said first flow line (106) from said collection tank (104) to said electrocoagulation unit (102) at a first flow rate, wherein said control unit gradually increases said first flow rate by increasing a speed of said electrocoagulation feed pump over a period of time, wherein said electrocoagulation feed pump (108) is electrically connected to said control unit;
automatically activate a PH sensor (110) to measure a PH of said waste water when said electrocoagulation feed pump (108) is activated, wherein said PH sensor (110) is placed in said first flow line (106); and
automatically activate a first dosing pump (112) to pump acid or alkali from a PH correction tank (114) to maintain the PH of said waste water within a threshold range of 6 to 9, wherein said control unit automatically activates said first dosing pump (112) when the measured PH of said waste water is not within said threshold range,
wherein said control unit provides power to said plurality of electrode (406) to coagulate said waste water to remove contaminates when flows from the bottom of said electrode assembly to the top of said electrode assembly inside said electrocoagulation unit (102), wherein said electrocoagulation unit (102) comprises a first outlet valve (116) that outputs the coagulated waste water to a clarifier (120) through a second flow line (118).

2. The automated system as claimed in claim 1, wherein said electrocoagulation unit (102) comprises an air grid (122) that is placed below the electrode assembly, wherein said air grid (122) is automatically activated by said control unit at predetermine intervals for providing air purging to improve electrocoagulation process while said waste water is electro-coagulated inside said electrocoagulation unit (102).

3. The automated system as claimed in claim 1, wherein said automated system comprises a thyristor based control unit that is electrically connected to said electrocoagulation unit (102), wherein said thyristor based control unit controls a first conductor and a second conductor that provide positive and negative current to said plurality of anodes and said plurality of cathodes respectively during an electrocoagulation process, wherein said thyristor based control unit reverses the current that is supplied to said first conductor and said second conductor by polarity reversal at a predetermine time interval to remove contaminants and metallic oxides deposited on said plurality of electrodes (406) and even consumption of said plurality of electrodes (406) when said waste water is electro-coagulated inside said electrocoagulation unit(102).

4. The automated system as claimed in claim 1, wherein said automated system comprises a polymer dosing pump (124) that is connected to a polymer dosing tank (126), wherein said control unit is configured to activate said polymer dosing pump (124) to provide polymer dosage on said second flow line (118) when said first outlet valve (116) outputs the coagulated waste water from said electrocoagulation unit (102), wherein said polymer dosage mix with said coagulated waste water to obtain a flocculated waste water.

5. The automated system as claimed in claim 1, wherein said clarifier (120) receives said flocculated waste water, wherein said clarifier (120) filters said flocculated waste water to remove sludge and outputs sludge free waste water to a filter feed tank (128).

6. The automated system as claimed in claim 5, wherein said clarifier (120) comprises a sludge outlet valve (130), a first solenoid valve (132) and a second solenoid valve (134) that are electrically controlled by said control unit, wherein said control unit activates a sludge feed pump (135) to pump concentrated sludge to a first filter press (136) when said first solenoid valve (132) is in open position and said second solenoid valve (134) is in closed position or to a second filter press (138) when said first solenoid valve (132) is in closed position and said second solenoid valve (134) is in open position, for filtering water from said concentrated sludge.

7. The automated system as claimed in claim 5, wherein said clarifier (120) comprises a clarifier inlet valve (140) that is electrically controlled by said control unit, wherein said control unit opens said clarifier inlet valve (140) to receive said flocculated waste water by gravity when said sludge outlet valve (130) is in closed position.

8. The automated system as claimed in claim 5, wherein said clarifier comprises a clarifier outlet, wherein said clarifier outlet outputs said sludge free waste water to a filter feed tank.

9. The automated system as claimed in claim 5, wherein said first filter press (136) and said second filter press (138) recirculates water filtered from said concentrated sludge for further filter pressing and outputs treated water to said filter feed tank (128).

10. The automated system as claimed in claim 5, wherein said automated system comprises a pressure sand filter (142) and an activated carbon filter and/or iron removal filter (IRF) (144) that receive said sludge free waste water, wherein said pressure sand filter (142) and said activated carbon filter and/or iron removal filter (144) suspended solids and colloidal from said sludge free waste water and outputs (i) a carbon or IRF filtered water to an ultrafiltration (UF) feed tank (202) and (ii) a backwashed waste water to said collection tank (104).

11. The automated system as claimed in claim 10, wherein said automated system comprises a filter feed pump (146) that is connected to said filter feed tank (128), wherein said control unit activates said filter feed pump (146) to pump said sludge free waste water from said filter feed tank (128) to said pressure sand filter (142) and said activated carbon filter and/or iron removal filter (144) at a second flow rate, wherein said control unit gradually increases said second flow rate over a period of time to increase a flow of said sludge free waste water.

12. The automated system as claimed in claim 10, wherein said automated system comprises a UF system (204) that filters said carbon or IRF filtered water using a plurality of first filters (206) to remove colloidal particles, viruses, or large molecules and outputs a UF treated water to a first reverse osmosis (RO) feed tank (208).

13. The automated system as claimed in claim 11, wherein said UF system (204) comprises an UF inlet valve (210), an UF drain valve (212) and an UF service outlet valve (214) that are electrically controlled by said control unit, wherein said automated system comprises a UF feed pump (216) that is connected to said UF feed tank (202), wherein said control unit controls said UF feed pump (216) to pump said carbon or IRF filtered water from said UF feed tank (202) at a third flow rate when said UF inlet valve (210) is in open condition and said UF drain valve (212) and said UF service outlet valve (214) is in closed position, wherein said control unit gradually increases said third flow rate over a period of time to increase a flow of said carbon or IRF filtered water to said UF system (204).

14. The automated system as claimed in claim 13, wherein said UF system (204) comprises a UF backwash feed valve (218), a UF backwash inlet valve (220), and a UF bottom drain valve (222) that are electrically controlled by said control unit, wherein said control unit activates a UF backwash pump (224) to pump backwashed waste water from a backwash tank (226) when said UF inlet valve (210), said UF drain valve (212), said UF service outlet valve (214) and said UF bottom drain valve (222) are in closed position and when said UF backwash feed valve (218), said UF backwash inlet valve (220) are in open position, wherein said UF backwash feed valve (218), said UF backwash inlet valve (220), and said UF bottom drain valve (222) are closed after a predetermined time period.

15. The automated system as claimed in claim 12, wherein said automated system comprises a first RO system (228) that receives said UF treated water from said first reverse osmosis (RO) feed tank (208), wherein said first RO system (228) filters said UF treated water using a plurality of second filters (230) to remove ions, molecules and larger particles and outputs a first RO permeate water to a RO permeate or production tank (354) and a first RO reject water to a second reverse osmosis (RO) feed tank (304).

16. The automated system as claimed in claim 15, wherein said first RO system (228) comprises a first RO feed valve (232), a first RO inlet valve (234) and an Oxidation Reduction potential (ORP) drain valve (236) that are electrically controlled by said control unit, wherein said control unit activates
a first RO feed pump (238) to pump said UF treated water from said first reverse osmosis (RO) feed tank (208) at a fourth flow rate through a third flow line (240) when said first RO feed valve (232) and said RO first inlet valve (234) are in open position and when said ORP drain valve (236) is in closed position,
a first acid dosing pump (242) that is automatically activated using said control unit when a PH of said UF treated water is not within a threshold range to provide required acid dosage to said UF treated water in said third flow line (240),
a first anti-oxidant dosing pump (244) to provide required anti-oxidant dosage to said UF treated water in said third flow line (240), and
a first anti-scalant dosing pump (246) to provide required anti- scalant dosage to said UF treated water in said third flow line (240), wherein said control unit gradually increases said fourth flow rate over a period of time.

17. The automated system as claimed in claim 15, wherein said automated system comprises a second RO system (306) that receives said first RO reject water from said second reverse osmosis (RO) feed tank (304), wherein said second RO system (306) filters said first RO reject water using a plurality of third filters (308) to remove further ions, molecules and larger particles and outputs a second RO permeate water to said RO permeate or production Tank (354) and a second RO reject water to a third reverse osmosis (RO) feed tank (310).

18. The automated system as claimed in claim 17, wherein said second RO system (306) comprises a second RO feed valve (312), a second RO permeate valve (318) and a second reject valve (320) that are electrically controlled by said control unit, wherein said control unit activates a second RO feed pump (322) to pump said first RO reject water from said second reverse osmosis (RO) feed tank (304) through a fourth flow line (324) at a fifth flow rate when said second RO feed valve (312), said second RO permeate valve (318) are in open position and said second reject valve (320) is not in fully closed position, wherein said control unit activates a second acid dosing pump (326) when a PH of said first RO reject water is not within a threshold range, a second anti-oxidant dosing pump and a second anti-scalant dosing pump (328) to provide required acid dosage, anti-oxidant dosage and anti-scalant dosage respectively to said first RO reject water in said fourth flow line (324), wherein said control unit gradually increases said fifth flow rate over a period of time, wherein said second RO feed valve (312), and said second RO permeate valve (318) are closed and said second reject valve (320) is opened after a predefined time period.

19. The automated system as claimed in claim 17, wherein said automated system comprises a third RO system (330) that receives said second RO reject water from said third reverse osmosis (RO) feed tank (310), wherein said third RO system (330) filters said second RO reject water using a plurality of fifth filters (332) to remove further ions, molecules and larger particles and outputs a third RO permeate water to said RO permeate or production Tank (354) and a third RO reject water to an evaporation tank (302).

20. The automated system as claimed in claim 19, wherein said third RO system (330) comprises a third RO feed valve (334), a third RO permeate valve (340) and a third reject valve (342) that are electrically controlled by said control unit, wherein said control unit activates a third RO feed pump (344) to pump said second RO reject water from said third reverse osmosis (RO) feed tank (310) through a fifth flow line (346) at a sixth flow rate when said third RO feed valve (334), said third RO permeate valve (340) are in open position and said third reject valve (342) is in closed position, wherein said control unit activates a third acid dosing pump when a PH of said second RO reject water is not within a threshold range, a third anti-oxidant dosing pump, and a third anti-scalant dosing pump (350) to provide required acid dosage, and anti-oxidant dosage and anti-scalant dosage respectively to said second RO reject water in said fifth flow line (346), wherein said control unit gradually increases said sixth flow rate over a period of time, wherein said third RO feed valve (334), and said third RO permeate valve (340) are closed and said third reject valve (342) is opened after a predefined time period.

21. The automated system as claimed in claim 18, wherein said automated system comprises an evaporator (352) that receives said third RO reject water or fourth RO reject water from said evaporation tank (302), wherein said evaporator (352) evaporates said third RO reject water or fourth RO reject water to remove dissolved solids and collects the evaporated water or reusable water in a production tank (354) and outputs a evaporator reject water to an agitated thin film drier .

22. The automated system as claimed in claim 21, wherein said agitated thin film drier converts said evaporator reject water to dried solids.

23. The automated system as claimed in claim 1, wherein said automated system comprises an air blower (105) that is electrically connected to said control unit, wherein said control unit automatically activates said air blower (105) to agitate said waste water inside said collection tank (104) at first predefined intervals.

24. The automated system as claimed in claim 1, wherein said automated system comprises an electrocoagulation cleaning unit (148) that automatically cleans said electrocoagulation unit (102) at predefined time intervals, wherein electrocoagulation cleaning unit (148) is electrically connected to said control unit.

25. The automated system as claimed in claim 24, wherein said electrocoagulation cleaning unit (148) comprises;
a first drain valve (150) that is electrically controlled by said control unit, wherein said control unit opens the first drain valve (150) to drain the waste water that is remaining in said electrocoagulation unit (102) to said collection tank (104) for cleaning when the first inlet valve (107) is in closed position;
a fresh water inlet valve (152) that is electrically controlled by said control unit, wherein said control unit opens said fresh water inlet valve (152) to provide fresh water to said electrocoagulation unit (102) for removing solid particles when said first inlet valve (107), said first outlet valve (116), said first drain valve (150) are in closed position, wherein said fresh water is pumped from a fresh water tank to said electrocoagulation unit (102) using a fresh water feed pump, wherein said air grid (122) provides air inside said electrocoagulation unit (102) at predefined time interval to remove said solid particles between said plurality of electrodes (406) during fresh water cleaning, wherein said control unit opens said first drain valve (150) to drain the waste water inside said electrocoagulation unit (102) after fresh water cleaning;
an acid inlet valve (154) that is electrically controlled by said control unit, wherein said control unit opens said acid inlet valve (154) to provide acid to removes all debris present in between said plurality of electrodes (406) of said electrocoagulation unit (102) when said first inlet valve (107), said first outlet valve (116), said first drain valve (150), said fresh water inlet valve (152) and an acid outlet valve (156) are in closed position, wherein said acid is soaked inside the electrocoagulation unit (102) for a predetermined time period to remove the debris and metal oxides present in between said plurality of electrodes (406) when said acid inlet valve (154) and said acid outlet valve (156) are in closed position;
an acid cleaning pump (158) that is electrically connected to said control unit, wherein said acid cleaning pump (158) automatically pumps acids from an EC chemical storage tank (160) to said electrocoagulation unit (102) through said acid inlet valve (154) at a predetermined time interval when said first inlet valve (107), said first outlet valve (116), said first drain valve (150), said fresh water inlet valve (152) and said acid outlet valve (156) are in closed position;
said acid outlet valve (156) that is electrically connected to said control unit, wherein said control unit automatically opens said acid outlet valve (156) to drain the acids after cleaning to said EC chemical storage tank (160) at a predetermined time interval when said acid inlet valve (154), said first inlet valve (107), said first outlet valve (116) and said first drain valve (150) are in closed position,
wherein said control unit automatically opens said fresh water inlet valve (152) again to provide the fresh water for subsequent fresh water cleaning of said electrocoagulation unit (102) at a predetermined time interval when said first inlet valve (107), said first outlet valve (116), said first drain valve (150), said acid inlet valve (154) and said acid outlet valve (156).

26. The automated system as claimed in claim 24, wherein said control unit opens said first drain valve (150) to drain acid from said electrocoagulation unit (102) to said collection tank (104) after a predetermined number of acid cleanings.

27. The automated system as claimed in claim 13, wherein said UF system (204) comprises a UF cleaning unit that comprises
a UF chemical feed valve (256), a UF reject to drain valve (248), a UF flushing inlet valve (250) and a UF permeate to cleaning tank (CT) valve (254) that are electrically controlled by said control unit, wherein said control unit activates a UF backwash pump (224) to pump cleaning chemicals from a UF chemical storage tank (225) through said UF chemical feed valve (256) and rinse acids at said UF system (204) for cleaning when said UF chemical feed valve (256), said UF reject to drain valve (248), said UF flushing inlet valve (250) and said UF permeate to CT valve (254) are in open position,
a UF chemical recirculation valve (252) that is electrically controlled by said control unit, wherein said control unit activates said UF backwash pump (224) to recirculate cleaning chemicals to said UF system (204) for subsequent cleaning at predefined intervals when said UF chemical recirculation valve, said UF chemical feed valve (256), said UF reject to drain valve (248), said UF flushing inlet valve (250) and said UF permeate to CT valve (254) are in open position.

28. The automated system as claimed in claim 16, wherein said first RO system (228) comprises a first RO cleaning unit (229) that comprises
a first RO cleaning inlet valve (280), a first RO permeate to cleaning tank valve (278), a first RO reject drain valve (270), a first RO reject valve (268) and a first RO circulation valve (272) that are electrically controlled by said control unit, wherein said control unit activates a first RO cleaning pump (284) to flush cleaning chemicals into said first RO system (228) from a first RO cleaning system (229) when said first RO cleaning inlet valve (280), said first RO permeate to cleaning tank valve (278) and said first RO reject drain valve (270) are in open position and said first RO reject valve (268) is in closed position,
wherein when said first RO cleaning inlet valve (280), said first RO permeate to cleaning tank valve (278) and said first RO circulation valve (272) are in opened and when said first RO reject valve (268) is closed position, said control unit activates said first RO cleaning pump (284) to recirculate acids into said first RO system (228) through said first RO circulation valve (272) for further cleaning.

29. The automated system as claimed in claim 17, wherein said second RO system (306) comprises a second RO cleaning unit (354) that comprises
a second RO cleaning inlet valve (356), a second RO permeate to cleaning tank valve (358), a second RO reject drain valve (360), a second RO reject valve (320) and a second RO circulation valve (364) that are electrically controlled by said control unit, wherein said control unit activates a second RO cleaning pump (366) to flush cleaning chemicals into said second RO system (306) from said second RO cleaning system (354) when said second RO cleaning inlet valve (356), said second RO permeate to cleaning tank valve (358) and said second RO reject drain valve (360) are in open position,
wherein when said second RO cleaning inlet valve (356), said second RO permeate to cleaning tank valve (358) and said second RO circulation valve (364) are in opened and when said second RO reject valve (320) is closed position, said control unit activates said second RO cleaning pump (366) to recirculate acids into said second RO system (306) through said second RO circulation valve (364) for further cleaning.
, Description:BACKGROUND
Technical Field
[0001] Embodiments of this disclosure generally relate to waste water treatment, more particularly, to an automated waste water recycling system using advanced electro-coagulation unit.
Description of the Related Art
[0002] The term ’waste water’ is commonly used to refer to any of the numerous aqueous streams containing pollutants and contaminants that arise in industrial and other contexts. Such waste waters are also referred to as effluent. Some of the engineering and process industries effluents (waste water) that can be treated in the method, Device, systems and processes according to the invention are Textile processing, dyeing, Chemicals, Finishing, Leather, Pharmaceuticals, Cement, Diary, Food processing, Slaughter house, beverages, distilleries, Papers, Steel manufacturing, Electroplating, Oil& Gas, Nuclear (Uranium waste water), Mining, Coal, Washing, Semiconductor sector, Abattoirs, Hotel, Hospitals, Restaurants, granite& marble processing and other industries using huge amount of water. Said term is also used in the domestic and municipal context where different water streams arise such as for example. Drinking water supply, sewage, grey water etc. The Term is also used to refer seawater, brackish water and similar water bodies or sources.
[0003] Wastewater treatment is a process used to convert wastewater into an effluent (outflowing of water to a receiving body of water) that can be returned to the water cycle with minimal impact on the environment or directly reused. The latter is called water reclamation because treated wastewater can then be used for other purposes. The treatment process takes place in a wastewater treatment plant (WWTP), often referred to as a Water Resource Recovery Facility (WRRF) or a sewage / Effluent treatment plant. Pollutants in municipal wastewater (households and small industries) are removed or broken down
[0004] Prior art techniques indicate that a relative degree of success in purifying such wastewaters can be achieved by passing bubbles of gases through a large tank containing industrial wastewater, whereby rising gas bubbles, having a laminar flow through the tank, occlude or become attached to some of the particulate matter. The thus treated particles tend to be less dense than water and accordingly rise to near the surface of the liquid within the tank where they can be skimmed off. Often these processes are combined with various chemical treatments. Even then, such prior art techniques are time consuming and relatively inefficient. Generally, prior art methods and apparatus cannot economically treat wastewater as quickly as it is generated in a large scale industrial process so as to satisfactorily remove pollutants therein.
[0005] Electro-coagulation treatment devices are also referred to as electro coagulators, electro coagulating reactors, EC reactors, ECRs, electrolysis and by several other expressions. Electro coagulation is analogous to chemical coagulation. Chemical coagulating materials are added to the waste water to separate out suspended, colloidal and emulsified matter contained therein. Chemical coagulants, coagulants for short, destabilize suspensions, colloids and emulsions by neutralizing their charges. The destabilized solid matter from the suspensions and colloids agglomerates and precipitates out. In case of emulsions the contaminant liquid coalesces and forms a separate fluid phase which is the separated out.
[0006] If flocculants have also been added or if the coagulants themselves form flocculates the said solid matter is trapped in the flocculation and rises to the water surface. It is then removed by skimming or other known separation means. Floatation agents are also sometimes used. The resulting contaminant liquid phase formed when an emulsion is destabilized is removed by decantation or other known separation processes.
[0007] EC is generally speaking more versatile than chemical coagulation in the range of said waste water than can be handled, in the range of reactions for contaminant removal that can be carried out therein and, in the extent, and comprehensiveness of contaminant removal. A disadvantage of the chemical method is that the un-reacted chemical coagulants themselves constitute contaminants and introduce secondary pollution. Also, remnants from the reactions involving the coagulants and other additives also generate secondary pollution. They may also contain impurities that contaminate the waste water stream being processed.
[0008] Thus, there remains a need for an automated waste water recycling system for treating and recycling waste water with improved efficiency without aforementioned drawbacks.

SUMMARY
[0009] The present disclosure provides an automated system for treating waste water, comprising:
an electrocoagulation (EC) unit that is connected to a collection tank through a first flow line for receiving waste water, wherein the electrocoagulation unit comprises:
a nonconductive outer shell;
an electrode assembly that is placed inside the nonconductive outer shell comprising
a plurality of electrodes that are arranged in parallel and being closely spaced in a vertical position between the plurality of electrodes, wherein the waste water flows between the plurality of electrodes from a bottom of the electrode assembly to a top of the electrode assembly, wherein the plurality of electrodes comprises a plurality of anodes and a plurality of cathodes; and
a plurality of holders that tightly holds the plurality of electrodes;
a first inlet valve that is connected to the first flow line feeds the waste water inside the electrocoagulation unit; and
a control unit that is electrically connected to the electrocoagulation unit, wherein the control unit is configured to
activate an electrocoagulation feed pump to pump the waste water through the first flow line from the collection tank to the electrocoagulation unit at a first flow rate, wherein the control unit gradually increases the first flow rate by increasing a speed of the electrocoagulation feed pump over a period of time, wherein the electrocoagulation feed pump is electrically connected to the control unit;
automatically activate a PH sensor to measure a PH of the waste water when the electrocoagulation feed pump is activated, wherein the PH sensor is placed in the first flow line; and
automatically activate a first dosing pump to pump acid or alkali from a PH correction tank to maintain the PH of the waste water within a threshold range of 6 to 9, wherein the control unit automatically activates the first dosing pump when the measured PH of the waste water is not within the threshold range,
wherein the control unit provides power to the plurality of electrode to coagulate the waste water to remove contaminates when flows from the bottom of the electrode assembly to the top of the electrode assembly inside the electrocoagulation unit, wherein the electrocoagulation unit comprises a first outlet valve that outputs the coagulated waste water to a clarifier through a second flow line.
[0010] According to an embodiment, the electrocoagulation unit comprises an air grid that is placed below the electrode assembly, wherein the air grid is automatically activated by the control unit at predetermine intervals for providing air purging to improve electrocoagulation process while the waste water is electro-coagulated inside the electrocoagulation unit.
[0011] According to another embodiment, the automated system comprises a thyristor based control unit that is electrically connected to the electrocoagulation unit, wherein the thyristor based control unit controls a first conductor and a second conductor that provide positive and negative current to the plurality of anodes and the plurality of cathodes respectively during an electrocoagulation process, wherein the thyristor based control unit reverses the current that is supplied to the first conductor and the second conductor by polarity reversal at a predetermine time interval to remove contaminants and metallic oxides deposited on the plurality of electrodes and even consumption of the plurality of electrodes when the waste water is electro-coagulated inside the electrocoagulation unit.
[0012] According to yet another embodiment, the automated system comprises a polymer dosing pump that is connected to a polymer dosing tank, wherein the control unit is configured to activate the polymer dosing pump to provide polymer dosage on the second flow line when the first outlet valve outputs the coagulated waste water from the electrocoagulation unit, wherein the polymer dosage mix with the coagulated waste water to obtain a flocculated waste water.
[0013] According to yet another embodiment, the clarifier receives the flocculated waste water, wherein the clarifier filters the flocculated waste water to remove sludge and outputs sludge free waste water to a filter feed tank.
[0014] According to yet another embodiment, the clarifier comprises a sludge outlet valve, a first solenoid valve and a second solenoid valve that are electrically controlled by the control unit, wherein the control unit activates a sludge feed pump to pump concentrated sludge to a first filter press when the first solenoid valve is in open position and the second solenoid valve is in closed position or to a second filter press when the first solenoid valve is in closed position and the second solenoid valve is in open position, for filtering water from the concentrated sludge.
[0015] According to yet another embodiment, the clarifier comprises a clarifier inlet valve that is electrically controlled by the control unit, wherein the control unit opens the clarifier inlet valve to receive the flocculated waste water by gravity when the sludge outlet valve is in closed position.
[0016] According to yet another embodiment, the clarifier comprises a clarifier outlet, wherein the clarifier outlet outputs the sludge free waste water to a filter feed tank.
[0017] According to yet another embodiment, the first filter press and the second filter press recirculates water filtered from the concentrated sludge for further filter pressing and outputs treated water to the filter feed tank.
[0018] According to yet another embodiment, the automated system comprises a pressure sand filter and an activated carbon filter and/or iron removal filter (IRF) that receive the sludge free waste water, wherein the pressure sand filter and the activated carbon filter and/or iron removal filter filters the suspended solids and colloidal from the sludge free waste water and outputs (i) a carbon or IRF filtered water to an ultrafiltration (UF) feed tank and (ii) a backwashed waste water to the collection tank.
[0019] According to yet another embodiment, the automated system comprises a filter feed pump that is connected to the filter feed tank, wherein the control unit activates the filter feed pump to pump the sludge free waste water from the filter feed tank to the pressure sand filter and the activated carbon filter and/or iron removal filter at a second flow rate, wherein the control unit gradually increases the second flow rate over a period of time to increase a flow of the sludge free waste water.
[0020] According to yet another embodiment, the automated system comprises a UF system that filters the carbon or IRF filtered water using a plurality of first filters to remove colloidal particles, viruses, or large molecules and outputs a UF treated water to a first reverse osmosis (RO) feed tank.
[0021] According to yet another embodiment, the UF system comprises an UF inlet valve, an UF drain valve and an UF service outlet valve that are electrically controlled by the control unit, wherein the automated system comprises a UF feed pump that is connected to the UF feed tank, wherein the control unit controls the UF feed pump to pump the carbon or IRF filtered water from the UF feed tank at a third flow rate when the UF inlet valve is in open condition and the UF drain valve and the UF service outlet valve is in closed position, wherein the control unit gradually increases the third flow rate over a period of time to increase a flow of the carbon or IRF filtered water to the UF system.
[0022] According to yet another embodiment, the UF system comprises a UF backwash feed valve, a UF backwash inlet valve, and a UF bottom drain valve that are electrically controlled by the control unit, wherein the control unit activates a UF backwash pump to pump backwashed waste water from a backwash tank when the UF inlet valve, the UF drain valve, the UF service outlet valve and the UF bottom drain valve are in closed position and when the UF backwash feed valve, the UF backwash inlet valve are in open position, wherein the UF backwash feed valve, the UF backwash inlet valve, and the UF bottom drain valve are closed after a predetermined time period.
[0023] According to yet another embodiment, the automated system comprises a first RO system that receives the UF treated water from the first reverse osmosis (RO) feed tank, wherein the first RO system filters the UF treated water using a plurality of second filters to remove ions, molecules and larger particles and outputs a first RO permeate water to the RO permeate / production tank and a first RO reject water to a second reverse osmosis (RO) feed tank.
[0024] According to yet another embodiment, the first RO system comprises a first RO feed valve, a first RO inlet valve and an Oxidation Reduction potential (ORP) drain valve that are electrically controlled by the control unit, wherein the control unit activates
a first RO feed pump to pump the UF treated water from the first reverse osmosis (RO) feed tank at a fourth flow rate through a third flow line when the first RO feed valve and the RO first inlet valve are in open position and when the ORP drain valve is in closed position,
a first acid dosing pump that is automatically activated using the control unit when a PH of the UF treated water is not within a threshold range to provide required acid dosage to the UF treated water in the third flow line,
a first anti-oxidant dosing pump to provide required anti-oxidant dosage to the UF treated water in the third flow line, and
a first anti-scalant dosing pump to provide required anti- scalant dosage to the UF treated water in the third flow line, wherein the control unit gradually increases the fourth flow rate over a period of time.
[0025] According to yet another embodiment, the automated system comprises a second RO system that receives the first RO reject water from the second reverse osmosis (RO) feed tank, wherein the second RO system filters the first RO reject water using a plurality of third filters to remove further ions, molecules and larger particles and outputs a second RO permeate water to the RO permeate / production tank and a second RO reject water to a third reverse osmosis (RO) feed tank.
[0026] According to yet another embodiment, the second RO system comprises a second RO feed valve, a second RO permeate valve and a second reject valve that are electrically controlled by the control unit, wherein the control unit activates a second RO feed pump to pump the first RO reject water from the second reverse osmosis (RO) feed tank through a fourth flow line at a fifth flow rate when the second RO feed valve, the second RO permeate valve are in open position and the second reject valve is not in fully closed position, wherein the control unit activates a second acid dosing pump when a PH of the first RO reject water is not within a threshold range, a second anti-oxidant dosing pump and a second anti-scalant dosing pump to provide required acid dosage, anti-oxidant dosage and anti-scalant dosage respectively to the first RO reject water in the fourth flow line, wherein the control unit gradually increases the fifth flow rate over a period of time, wherein the second RO feed valve, and the second RO permeate valve are closed and the second reject valve is opened after a predefined time period.
[0027] According to yet another embodiment, the automated system comprises a third RO system that receives the second RO reject water from the third reverse osmosis (RO) feed tank, wherein the third RO system filters the second RO reject water using a plurality of fifth filters to remove further ions, molecules and larger particles and outputs a third RO permeate water to the RO permeate / production tank and a third RO reject water to a multiple effect evaporator system.
[0028] According to yet another embodiment, the third RO system comprises a third RO feed valve, a third RO permeate valve and a third reject valve that are electrically controlled by the control unit, wherein the control unit activates a third RO feed pump to pump the second RO reject water from the third reverse osmosis (RO) feed tank through a fifth flow line at a sixth flow rate when the third RO feed valve, the third RO permeate valve are in open position and the third reject valve is in closed position, wherein the control unit activates a third acid dosing pump when a PH of the second RO reject water is not within a threshold range, a third anti-oxidant dosing pump, and a third anti-scalant dosing pump to provide required acid dosage, and anti-oxidant dosage and anti-scalant dosage respectively to the second RO reject water in the fifth flow line, wherein the control unit gradually increases the sixth flow rate over a period of time, wherein the third RO feed valve, and the third RO permeate valve are closed and the third reject valve is opened after a predefined time period.
[0029] According to yet another embodiment, the automated system comprises a fourth RO system that receives the third RO reject water from the fourth reverse osmosis (RO) feed tank, wherein the fourth RO system filters the third RO reject water using a plurality of sixth filters to remove further ions, molecules and larger particles and outputs a fourth RO permeate water to the RO permeate / production tank and a fourth RO reject water to multiple effect evaporator system.
[0030] According to yet another embodiment, the fourth RO system comprises a fourth RO feed valve, a fourth RO inlet valve, a fourth RO permeate valve and a fourth reject valve that are electrically controlled by the control unit, wherein the control unit activates a fourth RO feed pump to pump the third RO reject water from the fourth reverse osmosis (RO) feed tank through a sixth flow line at a seventh flow rate when the fourth RO feed valve, the fourth RO inlet valve, the fourth RO permeate valve are in open position and the fourth reject valve is in closed position, wherein the control unit activates a fourth acid dosing pump when a PH of the third RO reject water is not within a threshold range, a fourth anti-oxidant dosing pump, and a fourth anti-scalant dosing pump to provide required acid dosage, and anti-oxidant dosage and anti-scalant dosage respectively to the third RO reject water in the sixth flow line, wherein the control unit gradually increases the seventh flow rate over a period of time, wherein the fourth RO feed valve, the fourth RO inlet valve and the fourth RO permeate valve are closed and the fourth reject valve is opened after a predefined time period.
[0031] According to yet another embodiment, the automated system comprises an evaporator that receives a reject slurry of the multiple effect evaporator system of third RO system or fourth RO system and further evaporated and outputs an evaporator condensate to the production tank and an evaporator reject water to an agitated thin film drier.
[0032] According to yet another embodiment, the agitated thin film drier converts the evaporator reject water to solids.
[0033] According to yet another embodiment, the automated system comprises an air blower that is electrically connected to the control unit, wherein the control unit automatically activates the air blower to agitate the waste water inside the collection tank at first predefined intervals.
[0034] According to yet another embodiment, the automated system comprises an electrocoagulation cleaning unit that automatically cleans the electrocoagulation unit at predefined time intervals, wherein electrocoagulation cleaning unit is electrically connected to the control unit.
[0035] According to yet another embodiment, the electrocoagulation cleaning unit comprises;
a first drain valve that is electrically controlled by the control unit, wherein the control unit opens the first drain valve to drain the waste water that is remaining in the electrocoagulation unit to the collection tank for cleaning when the first inlet valve is in closed position;
a fresh water inlet valve that is electrically controlled by the control unit, wherein the control unit opens the fresh water inlet valve to provide fresh water to the electrocoagulation unit for removing solid particles when the first inlet valve, the first outlet valve, the first drain valve are in closed position, wherein the fresh water is pumped from a fresh water tank to the electrocoagulation unit using a fresh water feed pump, wherein the air grid provides air inside the electrocoagulation unit at predefined time interval to remove the solid particles between the plurality of electrodes during fresh water cleaning, wherein the control unit opens the first drain valve to drain the waste water inside the electrocoagulation unit after fresh water cleaning;
an acid inlet valve that is electrically controlled by the control unit, wherein the control unit opens the acid inlet valve to provide acid to removes all debris present in between the plurality of electrodes of the electrocoagulation unit when the first inlet valve, the first outlet valve, the first drain valve, the fresh water inlet valve and an acid outlet valve are in closed position, wherein the acid is soaked inside the electrocoagulation unit for a predetermined time period to remove the debris and metal oxides present in between the plurality of electrodes when the acid inlet valve and the acid outlet valve are in closed position;
an acid cleaning pump that is electrically connected to the control unit, wherein the acid cleaning pump automatically pumps acids from a EC chemical storage tank to the electrocoagulation unit through the acid inlet valve at a predetermined time interval when the first inlet valve, the first outlet valve, the first drain valve, the fresh water inlet valve and the acid outlet valve are in closed position;
the acid outlet valve that is electrically connected to the control unit, wherein the control unit automatically opens the acid outlet valve to drain the acids after cleaning to the EC chemical storage tank at a predetermined time interval when the acid inlet valve, the first inlet valve, the first outlet valve and the first drain valve are in closed position,
wherein the control unit automatically opens the fresh water inlet valve again to provide the fresh water for subsequent fresh water cleaning of the electrocoagulation unit at a predetermined time interval when the first inlet valve, the first outlet valve, the first drain valve, the acid inlet valve and the acid outlet valve.
[0036] According to yet another embodiment, the control unit opens the first drain valve to drain acid from the electrocoagulation unit to the collection tank after a predetermined number of acid cleanings.
[0037] According to yet another embodiment, the UF system comprises a UF cleaning unit that comprises
a UF chemical feed valve, a UF reject to drain valve, a UF flushing inlet valve and a UF permeate to cleaning tank (CT) valve that are electrically controlled by the control unit, wherein the control unit activates a UF backwash pump to pump acids from a UF chemical storage tank through the UF chemical feed valve and rinse acids at the UF system for cleaning when the UF chemical feed valve, the UF reject to drain valve, the UF flushing inlet valve and the UF permeate to CT valve are in open position; and
a UF chemical recirculation valve that is electrically controlled by the control unit, wherein the control unit activates the UF backwash pump to recirculate acids to the UF system for subsequent cleaning at predefined intervals when the UF chemical recirculation valve, the UF chemical feed valve, the UF reject to drain valve, the UF flushing inlet valve and the UF permeate to CT valve are in open position
[0038] According to yet another embodiment, the first RO system comprises a first RO cleaning unit that comprises
a first RO cleaning inlet valve, a first RO permeate to cleaning tank valve, a first RO reject drain valve, a first RO reject valve and a first RO circulation valve that are electrically controlled by the control unit, wherein the control unit activates a first RO cleaning pump to flush acids into the first RO system from a first RO cleaning system when the first RO cleaning inlet valve, the first RO permeate to cleaning tank valve and the first RO reject drain valve are in open position and the first RO reject valve is in closed position,
wherein when the first RO cleaning inlet valve, the first RO permeate to cleaning tank valve and the first RO circulation valve are in opened and when the first RO reject valve is closed position, the control unit activates the first RO cleaning pump to recirculate acids into the first RO system through the first RO circulation valve for further cleaning.
[0039] According to yet another embodiment, the second RO system comprises a second RO cleaning unit that comprises
a second RO cleaning inlet valve, a second RO permeate to cleaning tank valve, a second RO reject drain valve, a second RO reject valve and a second RO circulation valve that are electrically controlled by the control unit, wherein the control unit activates a second RO cleaning pump to flush acids into the second RO system from the second RO cleaning system when the second RO cleaning inlet valve, the second RO permeate to cleaning tank valve and the second RO reject drain valve are in open position,
wherein when the second RO cleaning inlet valve, the second RO permeate to cleaning tank valve and the second RO circulation valve are in opened and when the second RO reject valve is closed position, the control unit activates the second RO cleaning pump to recirculate acids into the second RO system through the second RO circulation valve for further cleaning.
[0040] According to yet another embodiment, the third RO system comprises a third RO cleaning unit that comprises
a third RO cleaning inlet valve, a third RO permeate to cleaning tank valve, a third RO reject drain valve, a third RO reject valve and a third RO circulation valve that are electrically controlled by the control unit, wherein the control unit activates a third RO cleaning pump to flush acids into the third RO system from the second RO cleaning system when the third RO cleaning inlet valve, the third RO permeate to cleaning tank valve and the third RO reject drain valve are in open position,
wherein when the third RO cleaning inlet valve, the third RO permeate to cleaning tank valve and the third RO circulation valve are in opened and when the third RO reject valve is closed position, the control unit activates the third RO cleaning pump to recirculate acids into the third RO system through the third RO circulation valve for further cleaning.
[0041] The automated system improves the efficiency of waste water treatment and produces reusable with 97% recovery of pure reusable water.
[0042] This automated system has found a novel application for the acid solution. The acid that is spent can be advantageously utilized by charging it into the waste water to be treated. The ferrous chloride in the spent solution reacts to form the hydroxides. The hydroxides are coagulating agents and coagulate/coalesce colloidal suspensions and emulsions. The formation of hydroxide commences in the collection tank and continues in the EC unit. This automated system thus provides another novel utilization of an inconvenient waste product/stream. The utilization of the ferrous/ferric chlorides reduces the requirement of the consumable electrodes in the EC unit which is another advantage of the automated system. A further advantage of the automated system is that the electrocoagulation reactions continue seamlessly from the collection tank, through the first flow line and in the device (or any other ECR that may be used). The automated system automatically dispose/drain the spent acid and the associated sludge after the acid cleaning process.
[0043] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS
[0044] The embodiments herein will be better understood from the following detailed description with reference to the drawings, in which:
[0045] FIG. 1 illustrates a system view of an automated waste water recycling system comprising an electrocoagulation unit, a clarifier and, a pressure sand filter and activated carbon filter and/or iron removal filter according to the embodiment herein;
[0046] FIG. 2 illustrates a system view of the automated waste water recycling system comprising an ultrafiltration system and a first reverse osmosis (RO) system according to an embodiment herein;
[0047] FIG. 3 illustrates a system view of the automated waste water recycling system comprising a second reverse osmosis (RO) system and a third reverse osmosis (RO) system according to an embodiment herein;
[0048] FIG. 4 illustrates a perspective view of the electrocoagulation unit of the FIG. 1 according to an embodiment herein; and
[0049] FIGS. 5A and 5B illustrates a process of treating waste water using the automated waste water recycling system of FIG. 1 according to an embodiment herein.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0050] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0051] As mentioned, there remains a need for an automated waste water recycling system for treating and recycling waste water with improved efficiency. Referring now to the drawings, and more particularly to FIGS. 1 through 5B, where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.
[0052] FIG. 1 illustrates a system view of an automated waste water recycling system comprising an electrocoagulation (EC) unit (102), a clarifier (120) and, a pressure sand filter (142|) and activated carbon filter and/or iron removal filter (144) according to the embodiment herein. The electrocoagulation (EC) unit (102) is connected to a collection tank (104) through a first flow line (106) for receiving waste water. The electrocoagulation unit (102) includes a nonconductive outer shell and an electrode assembly. The electrode assembly that is placed inside the nonconductive outer shell including a plurality of electrodes that are arranged in parallel and being closely spaced in a vertical position between the plurality of electrodes. In one embodiment, the nonconductive outer shell is made up of polypropylene material. In another embodiment, the plurality of electrodes may include ferrous/iron/aluminium plates. The waste water flows between the plurality of electrodes from a bottom of the electrode assembly to a top of the electrode assembly. The plurality of electrodes includes a plurality of anodes and a plurality of cathodes and a plurality of holders that tightly holds the plurality of electrodes. The automated system comprises a first inlet valve (107) that is connected to the first flow line (106) feeds the waste water inside the electrocoagulation unit (102) and a control unit that is electrically connected to the electrocoagulation unit (102). The first inlet valve (107) may be a ball valve or butterfly valve controlled by solenoid valve or any electronic valve or pneumatic actuator. The control unit is configured to activate an electrocoagulation feed pump (108) to pump the waste water through the first flow line (106) from the collection tank (104) to the electrocoagulation unit (102) at a first flow rate ranging from 0.1 m3/hour to 200 m3/hour. The control unit gradually increases the first flow rate by increasing a speed of the electrocoagulation feed pump (108). Once the desired flow rate is reached, the speed of the feed pump (108) is maintained at the same speed during the electrocoagulation process. The electrocoagulation feed pump (108) is electrically connected to the control unit. The control unit automatically activates a PH sensor (110) to measure a PH of the waste water when the electrocoagulation feed pump (108) is activated. The PH sensor (110) is placed in the first flow line (106). The control unit automatically activates a first dosing pump (112) to pump acid or alkali from a PH correction tank (114) to maintain the PH of the waste water within a threshold range of 6 to 8. The control unit automatically activates the first dosing pump (112) when the measured PH of the waste water is not within the threshold range. The control unit provides power to the plurality of electrode to coagulate the waste water to remove contaminates when flows from the bottom of the electrode assembly to the top of the electrode assembly inside the electrocoagulation unit (102). The electrocoagulation unit (102) includes a first outlet valve (116) that outputs the coagulated waste water to the clarifier (120) through a second flow line (118).
[0053] The electrocoagulation unit (102) includes an air grid (122) that is placed below the electrode assembly. The air grid (122) is automatically activated by the control unit at predetermine intervals for providing air purging to improve electrocoagulation process while the waste water is electro-coagulated inside the electrocoagulation unit (102). The automated system includes a thyristor based control unit that is electrically connected to the electrocoagulation unit (102). The thyristor-based control unit controls a first conductor and a second conductor that provides positive and negative current to the plurality of anodes and the plurality of cathodes respectively during an electrocoagulation process. In an embodiment, a DC power is connected to a plurality of end plates and/or center plates. The plurality of plates that needs to be connected to the DC power may be determined based on waste water TDS and other parameters. The thyristor based control unit reverses the current that is supplied to the first conductor and the second conductor by polarity reversal at a predetermine time interval to remove contaminants and metallic oxides deposited on the plurality of electrodes and even consumption of the plurality of electrodes when the waste water is electro-coagulated inside the electrocoagulation unit (102). The polarity reversal is performed to maximize productivity, minimize downtime and reduce power consumption. The timing and frequency of polarity reversals can be predefined on the control system and the polarity reversal function is automatically performed by the control system with necessary electrical protective functions at the predefined intervals. The automated system includes a polymer dosing pump (124) that is connected to a polymer dosing tank (126). The control unit is configured to activate the polymer dosing pump (124) to provide polymer dosage on the second flow line (118) when the first outlet valve (116) outputs the coagulated waste water from the electrocoagulation unit (102). The polymer dosage mix with the coagulated waste water to obtain a flocculated waste water.
[0054] The clarifier (120) receives the flocculated waste water. The clarifier (120) settles down the solids of the flocculated waste water at the bottom to remove sludge and overflow sludge free waste water to a filter feed tank (128). The clarifier (120) may be Floatation type Dissolved Air Flotation (DAF) Clarifier, sedimentation type circular clarifier or Lamella Clarifier, HRSC Clarifier or Settling Tank etc. The clarifier (120) further includes a sludge outlet valve (130), a first solenoid valve (132) and a second solenoid valve (134) that are electrically controlled by the control unit. The control unit activates a sludge feed pump (135) to pump concentrated sludge to a first filter press (136) when the first solenoid valve (132) is in open position and the second solenoid valve (134) is in closed position or to a second filter press (138) when the first solenoid valve (132) is in closed position and the second solenoid valve (134) is in open position, for filtering water from the concentrated sludge. The clarifier (120) further includes a clarifier inlet valve (140) that is electrically controlled by the control unit. The control unit opens the clarifier inlet valve (140) to receive the flocculated waste water by gravity when the sludge outlet valve (130) is in closed position. The clarifier (120) further includes a clarifier outlet. The clarifier outlet outputs the sludge free waste water to a filter feed tank (128). The first filter press (136) and the second filter press (138) recirculates water filtered from the concentrated sludge for further filter pressing and outputs treated water to the filter feed tank (128).
[0055] The pressure sand filter (142) and the activated carbon filter and/or iron removal filter (IRF) (144) receives the sludge free waste water. The pressure sand filter (142) and the activated carbon filter and/or iron removal filter (144) filters suspended solids and colloidal from the sludge free waste water and outputs (i) a carbon or IRF filtered water to an ultrafiltration (UF) feed tank (202) and (ii) a backwashed waste water to the collection tank (104). The automated system further includes a filter feed pump (146) that is connected to the filter feed tank (128). The control unit activates the filter feed pump (146) to pump the sludge free waste water from the filter feed tank (128) to the pressure sand filter (142) and the activated carbon filter and/or iron removal filter (144) at a second flow rate. The control unit gradually increases the second flow rate over a period of time to increase a flow of the sludge free waste water. The automated system includes an air blower (105) that is electrically connected to the control unit. The control unit automatically activates the air blower 105 to agitate the waste water inside the collection tank (104) at first predefined intervals.
[0056] The automated system includes an electrocoagulation cleaning unit (148) that automatically cleans the electrocoagulation unit (102) at predefined time intervals. The electrocoagulation cleaning unit (148) is electrically connected to the control unit. The electrocoagulation cleaning unit includes a first drain valve (150) that is electrically controlled by the control unit. The control unit opens the first drain valve (150) to drain the waste water that is remaining in the electrocoagulation unit (102) to the collection tank (104) for cleaning when the first inlet valve (107) is in closed position. The electrocoagulation cleaning unit (148) includes a fresh water inlet valve (152) that is electrically controlled by the control unit. The control unit opens the fresh water inlet valve (152) to provide fresh water to the electrocoagulation unit 102 for removing solid particles when the first inlet valve (107), the first outlet valve 116, the first drain valve (150) are in closed position. The fresh water is pumped from a fresh water tank to the electrocoagulation unit (102) using a fresh water feed pump. The air grid (122) provides air inside the electrocoagulation unit (104) at predefined time interval to remove the solid particles between the plurality of electrodes during fresh water cleaning. The control unit opens the first drain valve (150) to drain the waste water inside the electrocoagulation unit (102) after fresh water cleaning.
[0057] The electrocoagulation cleaning unit (148) includes an acid inlet valve (154) that is electrically controlled by the control unit. The control unit opens the acid inlet valve (154) to provide acid to removes all debris present in between the plurality of electrodes of the electrocoagulation unit (102) when the first inlet valve (107), the first outlet valve (116), the first drain valve (150), the fresh water inlet valve (152) and an acid outlet valve (156) are in closed position. The acid is soaked inside the electrocoagulation unit (102) for a predetermined time period to remove the debris and metal oxides present in between the plurality of electrodes when the acid inlet valve (154) and the acid outlet valve (156) are in closed position. The electrocoagulation cleaning unit (148) includes an acid cleaning pump (158) that is electrically connected to the control unit. The acid cleaning pump (158) automatically pumps cleaning chemicals from an EC chemical storage tank (160) to the electrocoagulation unit (102) through the acid inlet valve (154) at a predetermined time interval when the first inlet valve (107), the first outlet valve (116), the first drain valve (150), the fresh water inlet valve (152) and the acid outlet valve (156) are in closed position.
[0058] The acid outlet valve (156) that is electrically connected to the control unit. The control unit automatically opens the acid outlet valve (156) to drain the acids after cleaning to the EC chemical storage tank (160) at a predetermined time interval when the acid inlet valve (154), the first inlet valve (107), the first outlet valve (116) and the first drain valve (150) are in closed position. The control unit automatically opens the fresh water inlet valve (152) again to provide the fresh water for subsequent fresh water cleaning of the electrocoagulation unit (102) at a predetermined time interval when the first inlet valve (107), the first outlet valve (116), the first drain valve (150), the acid inlet valve (154) and the acid outlet valve (156). The control unit opens the first drain valve (150) to drain acid from the electrocoagulation unit (102) to the collection tank 104 after a predetermined number of acid cleanings. In an embodiment, any of the above mentioned valves may be a ball valve or butterfly valve controlled by a solenoid valve or an electric valve or a pneumatic actuator.
[0059] FIG. 2 illustrates a system view of the automated waste water recycling system comprising an ultrafiltration (UF) system (204) and a first reverse osmosis (RO) (228) system according to an embodiment herein. The UF system (204) filters the carbon or IRF filtered water using a plurality of first filters (206) to remove colloidal particles, viruses, or large molecules and outputs a UF treated water to a first reverse osmosis (RO) feed tank (208). The plurality of first filters may be a membrane filters or spiral wound sheet type membrane or hollow fiber membrane. The UF system (204) further includes an UF inlet valve (210), an UF drain valve (212) and an UF service outlet valve (214) that are electrically controlled by the control unit. The automated system further includes a UF feed pump (216) that is connected to the UF feed tank (202). The control unit controls the UF feed pump (216) to pump the carbon or IRF filtered water from the UF feed tank (202) at a third flow rate when the UF inlet valve (210) is in open condition and the UF drain valve (212) and the UF service outlet valve (214) is in closed position. The control unit gradually increases the third flow rate over a period of time to increase a flow of the carbon or IRF filtered water to the UF system (204). The UF system (204) further includes a UF backwash feed valve (218), a UF backwash inlet valve (220), and a UF bottom drain valve (222) that are electrically controlled by the control unit. The control unit activates a UF backwash pump (224) to pump backwashed waste water from a backwash tank (226) when the UF inlet valve (210), the UF drain valve (212), the UF service outlet valve (214) and the UF bottom drain valve (222) are in closed position and when the UF backwash feed valve (218), the UF backwash inlet valve (220) are in open position. The UF backwash feed valve (218), the UF backwash inlet valve (220), and the UF bottom drain valve (222) are closed after a predetermined time period. The first RO system (228) that receives the UF treated water from the first reverse osmosis (RO) feed tank (208). The first RO system (228) filters the UF treated water using a plurality of second filters (230) to remove ions, molecules and larger particles and outputs a first RO permeate water to a RO permeate / production tank and a first RO reject water to a second reverse osmosis (RO) feed tank. The plurality of second filters may be a RO filter, spiral wound brackish water or sea water membranes or low fouling RO membranes and circular disc membranes.
[0060] The first RO system (228) includes a first RO feed valve (232), a first RO inlet valve (234) and an Oxidation Reduction potential (ORP) drain valve (236) that are electrically controlled by the control unit. The control unit activates a first RO feed pump (238) to pump the UF treated water from the first reverse osmosis (RO) feed tank (208) at a fourth flow rate through a third flow line (240) when the first RO feed valve (232) and the RO first inlet valve (234) are in open position and when the ORP drain valve (236) is in closed position. The automated system includes a first acid dosing pump (242) that is automatically activated using the control unit when a PH of the UF treated water is not within a threshold range to provide required acid dosage to the UF treated water in the third flow line (240). The automated system includes a first anti-oxidant dosing pump (244) to provide required anti-oxidant dosage to the UF treated water in the third flow line (240) and a first anti-scalant dosing pump (246) to provide required anti- scalant dosage to the UF treated water in the third flow line (240). The control unit gradually increases the fourth flow rate over a period of time.
[0061] The UF system (204) includes a UF cleaning unit. The UF cleaning unit includes a UF chemical feed valve (256), a UF reject to drain valve (248), a UF flushing inlet valve (250) and a UF permeate to cleaning tank (CT) valve (254) that are electrically controlled by the control unit. The control unit activates a UF backwash pump (224) to pump cleaning chemicals such as organic and inorganic acids, alkalis and chlorine based cleaning chemicals from a UF chemical storage tank (225) through the UF chemical feed valve (256) and rinse acids at the UF system (204) for cleaning when the UF chemical feed valve (256), the UF reject to drain valve (248), the UF flushing inlet valve (250) and the UF permeate to CT valve (254) are in open position, a UF chemical recirculation valve (252) that is electrically controlled by the control unit. The control unit activates the UF backwash pump (224) to recirculate acids to the UF system (204) for subsequent cleaning at predefined intervals when the UF chemical recirculation valve, the UF chemical feed valve (256), the UF reject to drain valve (248), the UF flushing inlet valve (250) and the UF permeate to CT valve (254) are in open position.
[0062] The first RO system (228) includes a first RO cleaning unit (229). The first RO cleaning unit (229) includes a first RO cleaning inlet valve (280), a first RO permeate to cleaning tank valve (278), a first RO reject drain valve (270), a first RO reject valve (268) and a first RO circulation valve (272) that are electrically controlled by the control unit. The control unit activates a first RO cleaning pump (284) to flush cleaning chemicals such as organic and inorganic acids, alkalis and chlorine based cleaning chemicals into the first RO system (228) from a first RO cleaning system (229) when the first RO cleaning inlet valve (280), the first RO permeate to cleaning tank valve (278) and the first RO reject drain valve (270) are in open position and the first RO reject valve (268) is in closed position. When the first RO cleaning inlet valve (280), the first RO permeate to cleaning tank valve (278) and the first RO circulation valve (272) are in open position and when the first RO reject valve (268) is closed position, the control unit activates the first RO cleaning pump (284) to recirculate the cleaning chemicals into the first RO system (228) through the first RO circulation valve (272) for further cleaning. In an embodiment, any of the above mentioned valves may be a solenoid valve or an electronic valve.
[0063] FIG. 3 illustrates a system view of the automated waste water recycling system comprising a second reverse osmosis (RO) system (306) and a third reverse osmosis (RO) system (330) according to an embodiment herein. The second RO system (306) that receives the first RO reject water from the second reverse osmosis (RO) feed tank (304). The second RO system (306) filters the first RO reject water using a plurality of third filters (308) to remove further ions, molecules and larger particles and outputs a second RO permeate water to the evaporation tank (302) and a second RO reject water to a third reverse osmosis (RO) feed tank (310).
[0064] The second RO system (306) further includes a second RO feed valve (312), a second RO permeate valve (318) and a second RO reject valve (320) that are electrically controlled by the control unit. The control unit activates a second RO feed pump (322) to pump the first RO reject water from the second reverse osmosis (RO) feed tank (304) through a fourth flow line (324) at a fifth flow rate when the second RO feed valve (312), the second RO permeate valve (318) are in open position and the second RO reject valve (320) is not in fully closed position. The control unit activates a second acid dosing pump (326) when a PH of the first RO reject water is not within a threshold range, a second anti-oxidant dosing pump and a second anti-scalant dosing pump (328) to provide required acid dosage, anti-oxidant dosage and anti-scalant dosage respectively to the first RO reject water in the fourth flow line (324). The control unit gradually increases the fifth flow rate over a period of time. The second RO feed valve (312), and the second RO permeate valve (318) are closed and the second RO reject valve (320) is opened after a predefined time period.
[0065] The third RO system (330) receives the second RO reject water from the third reverse osmosis (RO) feed tank (310). The third RO system (330) filters the second RO reject water using a plurality of fifth filters (332) to remove further ions, molecules and larger particles and outputs a third RO permeate water to the RO permeate / production tank (354) and a third RO reject water to an evaporation tank (302). The third RO system (330) further includes a third RO feed valve (334), a third RO permeate valve (340) and a third RO reject valve (342) that are electrically controlled by the control unit. The control unit activates a third RO feed pump (344) to pump the second RO reject water from the third reverse osmosis (RO) feed tank (310) through a fifth flow line (346) at a sixth flow rate when the third RO feed valve (334), the third RO permeate valve (340) are in open position and the third RO reject valve (342) is in closed position. The control unit activates a third acid dosing pump (348) when a PH of the second RO reject water is not within a threshold range, a third anti-oxidant dosing pump, and a third anti-scalant dosing pump (350) to provide required acid dosage, and anti-oxidant dosage and anti-scalant dosage respectively to the second RO reject water in the fifth flow line (346). The control unit gradually increases the sixth flow rate over a period of time. The third RO feed valve (334), and the third RO permeate valve (340) are closed and the third RO reject valve (342) is opened after a predefined time period. In an embodiment, the automated system includes a fourth RO system for subsequent purification/purification of a third RO reject water. The automated system further comprises a fourth RO system that receives the third RO reject water from the fourth reverse osmosis (RO) feed tank. The fourth RO system filters the third RO reject water using a plurality of sixth filters to remove further ions, molecules and larger particles and outputs a fourth RO permeate water to the RO permeate / production tank (354) and a fourth RO reject water to multiple effect evaporator system.
[0066] The fourth RO system comprises a fourth RO feed valve, a fourth RO inlet valve, a fourth RO permeate valve and a fourth reject valve that are electrically controlled by the control unit, wherein the control unit activates a fourth RO feed pump to pump the third RO reject water from the fourth reverse osmosis (RO) feed tank through a sixth flow line at a seventh flow rate when the fourth RO feed valve, the fourth RO inlet valve, the fourth RO permeate valve are in open position and the fourth reject valve is in closed position, wherein the control unit activates a fourth acid dosing pump when a PH of the third RO reject water is not within a threshold range, a fourth anti-oxidant dosing pump, and a fourth anti-scalant dosing pump to provide required acid dosage, and anti-oxidant dosage and anti-scalant dosage respectively to the third RO reject water in the sixth flow line, wherein the control unit gradually increases the seventh flow rate over a period of time, wherein the fourth RO feed valve, the fourth RO inlet valve and the fourth RO permeate valve are closed and the fourth reject valve is opened after a predefined time period.
[0067] The automated system comprises an evaporator that receives a reject slurry of the multiple effect evaporator system of third RO system (330) or fourth RO system and further evaporated and outputs evaporator condensate to the production tank (354) and evaporator reject water to an agitated thin film drier. The agitated thin film drier converts the evaporator reject water to solids. The second RO system (306) includes a second RO cleaning unit (354) that further includes a second RO cleaning inlet valve (356), a second RO permeate to cleaning tank valve (358), a second RO reject drain valve (360), the second RO reject valve (320) and a second RO circulation valve (364) that are electrically controlled by the control unit. The control unit activates a second RO cleaning pump (366) to flush cleaning chemicals into the second RO system (306) from the second RO cleaning system (354) when the second RO cleaning inlet valve (356), the second RO permeate to cleaning tank valve (358) and the second RO reject drain valve (360) are in open position. When the second RO cleaning inlet valve (356), the second RO permeate to cleaning tank valve (358) and the second RO circulation valve (364) are in opened and when the second RO reject valve (320) is closed position, the control unit activates the second RO cleaning pump (366) to recirculate cleaning chemicals into the second RO system (306) through the second RO circulation valve (364) for further cleaning. In an embodiment, any of the above mentioned valves may be a ball valve or a butterfly valve controlled by a solenoid valve or any electronic valve or a pneumatic actuator.
[0068] The third RO system (330) includes a third RO cleaning unit that includes a third RO cleaning inlet valve (368), a third RO permeate to cleaning tank valve (370), a third RO reject drain valve (372), said third RO reject valve (342) and a third RO circulation valve (374) that are electrically controlled by the control unit. The control unit activates a third RO cleaning pump (376) to flush cleaning chemicals into the third RO system (330) from the second RO cleaning system (354) when the third RO cleaning inlet valve (368), the third RO permeate to cleaning tank valve (370) and the third RO reject drain valve (372) are in open position. When the third RO cleaning inlet valve (368), the third RO permeate to cleaning tank valve (370) and the third RO circulation valve (374) are in opened and when the third RO reject valve (342) is closed position, the control unit activates the third RO cleaning pump (376) to recirculate cleaning chemicals into the third RO system through the third RO circulation valve (374) for further cleaning.
[0069] FIG. 4 illustrates a perspective view of the electrocoagulation unit (102) of the FIG. 1 according to an embodiment herein. The electrocoagulation unit (102) includes a hoist (402), a lifting arrangement (404), a plurality of holders (406) and a plurality of electrodes (408). The hoist (402) control the lifting arrangement (404) to place the plurality of electrodes (408) inside the electrocoagulation unit (102). The lifting arrangement (404) is coupled to the plurality of holders (406) for lifting the plurality of electrodes (408). The plurality of holders (406) tightly holds the plurality of electrodes (408).
[0070] FIGS. 5A and 5B illustrates a process of treating waste water using the automated waste water recycling system of FIG. 1 according to an embodiment herein. At step 502, an industrial process is performed in a process house. At step 504, the collection/equalization tank (104) collects the waste water from the process house for filtering. At step 506, the air blower (105) agitates the waste water inside the collection tank (104) at predefined intervals. At step 508, a PH sensor (110) is automatically activated to measure a PH of the waste water when the electrocoagulation feed pump (108) is activated. The PH sensor (110) is placed in the first flow line (106) and the control unit automatically activates the first dosing pump (112) to pump acid or alkali from a PH correction tank (114) to maintain the PH of the waste water within a threshold range of 6 to 8 when the measured PH of the waste water is not within the threshold range.
[0071] At step 510, the electrocoagulation (EC) unit (102) is connected to the collection tank (104) through a first flow line (106) for receiving waste water. The control unit activates the electrocoagulation feed pump (108) to pump said waste water through the first flow line (106) from the collection tank (104) to the electrocoagulation unit (102) at a first flow rate. At step 512, the polymer dosing pump (124) is connected to the polymer dosing tank (126). The control unit is configured to activate the polymer dosing pump (124) to provide polymer dosage. At step 514, the clarifier (120) receives the flocculated waste water. The clarifier (120) removes the flocculated solids either by sedimentation or floatation from the flocculated waste water and outputs sludge free waste water to the filter feed tank (128). At step 516, the control unit activates the sludge feed pump (135) to pump concentrated sludge to the first filter press (136) when the first solenoid valve (132) is in open position and the second solenoid valve (134) is in closed position or to the second filter press (138) when the first solenoid valve (132) is in closed position and the second solenoid valve (134) is in open position, for filtering water from the concentrated sludge. At step 518, the first filter press and the second filter press remove the sludge from the concentrated sludge and treated water out to the filter feed tank (128). At step 520, the filter feed pump (146) pumps the sludge free waste water from the filter feed tank (128) to the pressure sand filter (142) and the activated carbon filter and/or iron removal filter (144). At step 522, the pressure sand filter (142) and the activated carbon filter and/or iron removal filter (IRF) (144) receive the sludge free waste water. The pressure sand filter (142) and the activated carbon filter and/or iron removal filter (144) filter suspended solids and colloidal from the sludge free waste water and outputs (i) a carbon or IRF filtered water to an ultrafiltration (UF) feed tank (202) and (ii) a backwashed waste water to the collection tank (104). At step 524, the UF feed pump (216) pumps the carbon or IRF filtered water from the UF feed tank (202) to the UF system (204).
[0072] At step 526, the UF system (204) filters the carbon or IRF filtered water using the plurality of first filters (206) to remove colloidal particles, viruses, or large molecules and outputs a UF treated water to the first reverse osmosis (RO) feed tank (208). At step 528, the first RO system (228) receives the UF treated water from the first reverse osmosis (RO) feed tank (208). At step 530, the first RO system (228) filters the UF treated water using a plurality of second filters (230) to remove ions, molecules and larger particles and outputs a first RO permeate water to the RO permeate / production tank (354) and a first RO reject water to the second reverse osmosis (RO) feed tank (304). At step 532, the second RO system (306) receives the first RO reject water from the second reverse osmosis (RO) feed tank (304). At step 534, the second RO system (306) filters the first RO reject water using a plurality of third filters (308) to remove further ions, molecules and larger particles and outputs a second RO permeate water to the RO permeate tank or production tank (354) and a second RO reject water to the third reverse osmosis (RO) feed tank (310). At step 536, the third RO system (330) receives the second RO reject water from the third reverse osmosis (RO) feed tank (310). At step 538, the third RO system (330) filters the second RO reject water using a plurality of fifth filters (332) to remove further ions, molecules and larger particles and outputs a third RO permeate water to the RO permeate tank or production tank (354) and a third RO reject water to an evaporation tank (302). At step 540, the evaporation tank collects the final stage RO reject (Third RO or Fourth RO) water. At step 542, the evaporator (352) receives the third RO reject water or fourth RO reject water from the evaporation tank (302). The evaporator (352) that receives a reject slurry of the multiple effect evaporator system of third RO system (330) or fourth RO system and further evaporated third RO reject water or fourth RO reject water to recover condensate water as reusable water in a RO permeate / production tank (354). At step 544, the agitated thin film drier converts the evaporator reject water to solids. At step 546, the dries solid are outputted from the automated waste water recycling system.
[0073] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the appended claims.