Master's Thesis

Assessment of pretreatment and membrane-based treatment of container cleaning wastewater and WWTP effluent for reuse applications

Final Thesis 3.55 MB

Author of thesis: Raha Khakpournezhad

Acad. year: 2026/2027

Supervisor: Dr. Alexios Nikolaos Theodorou

Reviewer: Mgr. Martina Repková, Ph.D.

Abstract:

Industrial water reuse can reduce the demand for freshwater in industrial processes and mitigate the environmental impacts associated with wastewater generation. However, container-cleaning wastewater can present a particular treatment challenge because of its variable composition, elevated organic loads, and dissolved chemical residues. This thesis investigated pretreatment and membrane-based treatment strategies for wastewater generated at THOR GmbH, with the aim of assessing its potential for internal water reuse.
Five wastewater streams were characterized, including pre-cleaning wastewater, main-cleaning wastewater, vacuum distillation (VACUDEST) streams, and treated wastewater treatment plant (WWTP) effluent. The streams showed substantial differences in organic load and conductivity. The main-cleaning wastewater, characterized by moderate organic contamination and comparatively low conductivity, was selected for subsequent membrane investigations. Coagulation–flocculation using ferric chloride and alum primarily reduced turbidity, while chemical oxygen demand (COD) and total organic carbon (TOC) reductions remained limited. Powdered activated carbon (PAC) adsorption also showed limited organic-matter reduction, whereas granular activated carbon (GAC) achieved substantial COD and TOC reductions under the investigated conditions, reaching approximately 75% and 78%, respectively, for the VACUDEST distillate.
A membrane treatment train consisting of microfiltration, activated carbon filtration, ultrafiltration, and reverse osmosis (RO) was subsequently investigated using main-cleaning wastewater. RO provided the largest reductions, with average reductions of approximately 96% for COD, TOC, turbidity, and conductivity, and the resulting permeate approached or met the indicative reuse-quality benchmarks selected in this study, including approximately 30–60 mg/L for COD,

Keywords:

Water reuse; Industrial wastewater treatment; Container-cleaning wastewater; Coagulation–flocculation; Activated carbon adsorption; Granular activated carbon; Membrane filtration; Reverse osmosis; Membrane fouling; Active ingredients.

Date of defence

30.09.2026

Result of the defence

Defended (thesis was successfully defended)

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Grading

A

Process of defence

The student presented her thesis and summarized its main content and results. The supervisor's and opponent's reports were subsequently read, and the student answered the questions raised in them. Additional questions were asked by the members of the examination committee: Assoc. Prof. P. Diviš: You used the COD parameter to quantify pollution; what does BOD stand for? What methods are used to determine these parameters? Dr. J. Másilko: Could you describe the sorption process in more detail? The student answered all questions from the committee clearly and satisfactorily. During the discussion, she demonstrated a very good understanding of the topic and was able to explain and discuss her results confidently. After the discussion, the committee proceeded with the evaluation of the thesis. The student showed excellent professional knowledge and the ability to independently present and defend her work.

Language of thesis

English

Faculty

Department

Study programme

Environmental Sciences and Engineering (NPAP_ENVI)

Composition of Committee

doc. Mgr. Renata Komendová, Ph.D. (člen)
doc. MVDr. Helena Zlámalová Gargošová, Ph.D. (člen)
prof. Ing. Jozef Krajčovič, Ph.D. (předseda)
doc. Mgr. Michaela Vašinová Galiová, Ph.D. (člen)
doc. Ing. Pavel Diviš, Ph.D. (místopředseda)
prof. Ing. Tomáš Weidlich, Ph.D. (člen)
Ing. Jiří Másilko, Ph.D. (člen)

Supervisor’s report
Dr. Alexios Nikolaos Theodorou

The submitted Master’s thesis was carried out within the framework of the double-degree programme between Brno University of Technology and RPTU Kaiserslautern-Landau, in collaboration with THOR GmbH, a global specialty chemical manufacturer, best known for producing high-performance additives and preservatives. The work addresses the treatment and potential reuse of industrial container-cleaning wastewater through the experimental evaluation of different pretreatment strategies and membrane-based treatment processes. Overall, the experimental programme was comprehensive and successfully addressed the objectives of the thesis.

From the perspective of supervision, I was very satisfied with Raha’s work throughout the project. As the experimental part of the thesis was conducted at THOR GmbH while my supervision was entirely remotely, regular and effective communication was particularly important. Throughout the entire project, Raha maintained very good communication, regularly discussed the progress of her work and any difficulties encountered, and was always receptive to feedback and recommendations.

I particularly appreciated her ability to work independently and to address problems as they arose. During the project, she encountered challenges both in the experimental work and later in the interpretation and presentation of the results and preparation of the thesis. She approached these issues responsibly, actively sought solutions, and made effective use of our consultations. Feedback provided during supervision was carefully considered and consistently incorporated into her work, including during the final stages of thesis preparation.

Raha was reliable, collaborative and engaged throughout the supervision process. She demonstrated persistence and a constructive attitude towards critical feedback, while progressively developing her ability to interpret her results and present them within the broader context of the research question.

Overall, I consider the thesis to be a very good piece of work addressing an industrially relevant research question through substantial experimental investigation. Raha successfully fulfilled the objectives of the thesis and demonstrated independence, responsibility, good problem-solving skills, and an excellent approach to supervision and collaboration. I recommend the submitted Master’s thesis for defence and propose the grade A – excellent.
Evaluation criteria Grade
Meeting the requirements of the thesis assignment A
Study of the literature and its processing A
Use of knowledge gained from the literature A
Quality of achieved results A
Interpretation and discussion of the results A
Conclusions of the thesis and their formulation A
Use of consultations in the process of writing A
Overall approach to solving assigned tasks A

Grade proposed by supervisor: A

Reviewer’s report
Mgr. Martina Repková, Ph.D.

This diploma thesis addresses the highly topical issue of industrial wastewater reuse within the framework of the circular economy and sustainable waste management. Wastewater from the cleaning of transport containers (IBC containers and drums) in the chemical industry poses a significant technological challenge due to its high and variable organic load, the presence of surfactants, and residues of biocidal substances.
The main objective of this study was to characterize five wastewater streams at the company THOR GmbH plant in Speyer, Germany, to evaluate the effectiveness of various pretreatment methods (coagulation/flocculation, adsorption on activated carbon), and to verify a cascade membrane system (Microfiltration – Activated Carbon Filtration – Ultrafiltration – Reverse Osmosis) for internal water recycling. The objectives set are clearly defined, scientifically sound, and have direct application potential in industrial practice.
The thesis is clearly structured into theoretical and experimental sections, supplemented by extensive appendix documentation.
The discussion of the results is of a high standard; the author compares the results with the scientific literature and correctly identifies the limitations of her research (shorter testing period, absence of blind tests for adsorption, limitations of analytical detection limits).
The thesis is written in English at a very good level, with a minimum of typos and grammatical errors. The graphic design, process flow diagrams (e.g., Figs. 2.1, 3.1, 3.3), and data visualizations in the graphs are clear and professional. The thesis meets all the requirements for doiploma’s theses at Brno University of Technology.
The graduate, Raha Khakpournezhad, has demonstrated the ability to conduct independent scientific and research work, critical thinking, and the systematic evaluation of experimental data. The thesis provides valuable insights for a specific industrial application at company THOR GmbH.
I recommend this diploma thesis for defense and propose that it be graded “Excellent” (A).
Evaluation criteria Grade
Meeting the requirements of the thesis assignment A
Logical structure of the thesis B
Quality of the achieved results A
Interpretation and discussion of the results A
Use of literature and citations A
Level of the language used A
Formal level of thesis and overall impression A
Conclusions of the thesis and their formulation A
Topics for thesis defence:
  1. Your results show that coagulation–flocculation with FeCl₃ and alum effectively reduced turbidity (up to 64–80%), but achieved only minimal removal of COD and TOC. Why did chemical destabilization fail to significantly remove organic pollutants in the container-cleaning wastewater, and what alternative coagulants or process modifications (e.g., pH adjustment, electrocoagulation) could potentially target this dissolved organic fraction?
  2. When evaluating activated carbon, GAC achieved up to 75–78% COD/TOC reduction, whereas PAC showed much lower efficiency. Since PAC and GAC were tested under different dosage ranges and contact times, how comparable are these results? Furthermore, how might the absence of a carbon-only blank (control sample) have influenced the observed TOC and turbidity values at high GAC dosages?"
  3. The study tracked specific active ingredients (MIT, CIT, phenoxyethanol) and found that lower-pressure stages (MF, ACF, UF) achieved negligible removal, while RO served as the main barrier (83–95% removal). How do solute properties such as molecular weight, charge, and polarity dictate this retention profile across the cascade?"
  4. During the laboratory experiments, membranes were only flushed with tap water after each run and no chemical cleaning was applied. In a real industrial plant, what chemical cleaning strategy (e.g., CIP – Cleaning-in-Place) would be necessary to maintain flux over longer periods?"

Grade proposed by reviewer: A

Responsibility: Mgr. et Mgr. Hana Odstrčilová