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Application of Ferrate for Enhancing Refinery Wastewater Treatment Quality toward Recycling and Reuse in Cooling Towers (Case Study: Tehran Oil Refinery)

Mirzajani, Mohammad | 2025

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  1. Type of Document: M.Sc. Thesis
  2. Language: Farsi
  3. Document No: 58505 (09)
  4. University: Sharif University of Technology
  5. Department: Civil Engineering
  6. Advisor(s): Khorashadizadeh, Farkhondeh
  7. Abstract:
  8. This study evaluated the feasibility of upgrading the treated effluent from the Tehran Oil Refinery wastewater treatment plant for reuse as cooling tower makeup water. Due to the high concentrations of dissolved solids, phosphate, silica, and COD, the direct use of this effluent causes scaling, corrosion, and biofouling in cooling systems. To address these issues, a hybrid advanced treatment train comprising pre-oxidation and coagulation using ferrate (Fe(VI)), followed by mixed-bed ion exchange (MB400) and a final remineralization stage, was employed. The goal was to simultaneously reduce organic, colloidal, and ionic loads with minimal energy and chemical consumption and to produce a chemically balanced water (LSI, RSI, PSI near equilibrium). Under the optimized conditions (0.1 mL/L ferrate dose at pH≈10), COD and phosphate removal reached 94% and 95%, while turbidity and SDI were reduced by over 80% and 50%, respectively. The ion-exchange process further decreased chloride, hardness, and silica by 91%, 80%, and 60%, reducing total dissolved solids from 1813 to about 11 mg/L. The final remineralization adjusted the LSI to the stable range (0–0.3) and yielded hardness and alkalinity around 80–90 mg/L as CaCO3, fully compliant with cooling-water standards. These results demonstrate that the Ferrate-IX-Remineralization hybrid process provides an effective, low-energy, and low-sludge alternative for polishing refinery effluents prior to reuse in cooling towers at the Tehran Oil Refinery.
  9. Keywords:
  10. Ion Exchange ; Water Reuse ; Cooling Tower ; Tehran Oil Refinery ; Remineralization ; Advanced Treatment Train ; Ferrate

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