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Case Study: Aria FLEX Custom Systems – Egypt

New Egyptian regulations prohibit wastewater discharge, causing industrial customer ETHYDCO to seek Pall's reliable filtration for challenging feed water.

Case Study: ETHYDCO Egypt

Industrial Water Treatment | EMEA: Alexandria, Egypt


As Egypt instituted new environmental regulations prohibiting wastewater discharge, the Egyptian Ethylene and Derivatives Company (ETHYDCO), the largest polyethylene (PE) production facility in Egypt, was determined to implement Zero Liquid Discharge (ZLD).


The initial design phase review estimated that the finished plant would consume a staggering 2,600 cubic meters per hour (m3/hr) and needed to optimize the water consumption through conservation and recycling, reducing it by nearly 70% at 700 m3/hr. Thus, to maximize the lifecycle of incoming water from The River Nile and preserve freshwater resources, ETHYDCO worked with Engineering for the Petroleum & Process Industries to provide Egypt’s first ZLD water treatment facility designed to recycle wastewater, allowing it to be continuously used in the production line.


The plant needed to identify a reliable filtration system capable of successfully handling inconsistent water quality with high total suspended solids (TSS) peaks in order to allow the treated water to achieve ZLD. The pretreatment is required before the ZLD as high efficiency reverse osmosis (HERO) systems call for highly filtered water, free of solids and with very low turbidity. Pall Water’s Aria FLEX custom water treatment solution was chosen as the pretreatment step for the ZLD system because the FLEX could treat challenging feed water, which comprised of treated effluent and water from The River Nile.


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Solution Overview

  • Met Environmental Requirements: The plant successfully achieves ZLD and meets environmental discharge regulations
  • Robust System: Capable of handling varying feed conditions while still operating at full capacity
  • Water for Reuse: High-quality, treated water is recycled and reused in the PE production process
  • Large-Scale System: The custom Aria FLEX was designed to operate between a range of 900 – 1,090 m3/hr of filtered water to meet the ZLD plant’s massive capacity
  • High-Recovery Membranes: Consistently deliver over 90% recovery at 100% production 

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Custom Water Solutions:

"Providing Successful Pretreatment of Challenging Feed Water at Egypt’s First ZLD Plant"
"Providing Successful Pretreatment of Challenging Feed Water at Egypt’s First ZLD Plant"
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  • The Challenge

    A reliable filtration solution was needed to provide pretreatment for ZLD. The solution would need to produce consistent, high-quality water from a feed source with high TSS peaks.

  • The Solution

    Pall’s ability to design the filtration system with special controls to allow operation at different feed scenarios was a differentiator, as Pall was able to provide a complete, smart solution for the varying feed water quality. The Pall Aria FLEX solution is based on six trains with a total filtration area of 22,800 m2.

  • The Results

    Pall Water’s Aria FLEX system treats all of the ETHYDCO facility’s collected wastewater. The water is purified to a high enough quality that it can be used again in the PE production process. Despite inconsistent water chemistry and difficulties associated with the feed water, Pall’s strong membrane fibers were capable of running constantly at high recovery levels, ranging from 91 – 93%, at 100% production. With Pall’s pretreatment system and the complete ZLD plant operational, ETHYDCO was able to meet all of the requisite norms of ZLD established by the Egyptian government to minimize water consumption and protect the country’s only life-giving aquifer, The River Nile.

  • Proven Solution

    With the successful completion of this project, ETHYDCO became the pioneer in ZLD and the model for all industries in Egypt and across other Gulf Cooperation Council (GCC) countries. It is also the first ethylene plant globally to achieve this. The achievement has made ETHYDCO 100% environmentally friendly with no liquid waste released into the environment. As a result, ETHYDCO was a recipient of the 2016 Global Water Awards.

  • Custom Water: Aria FLEX

    Pall Water's Aria FLEX custom water treatment systems are adaptable for your mid- to large-scale water treatment needs. Learn more about our flexible, custom solutions today!

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Learn More About ZLD Water Pretreatment

Pall Water's Aria FLEX custom water treatment systems provided quality water to an industrial plant, enabling the plant to achieve zero liquid discharge

Custom Water Solutions: Aria™ FLEX – MF / UF Systems

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Our modular microfiltration and ultrafiltration systems are customized for a wide range of capacities and scope needs, thus meeting even the largest and most complex water treatment challenges.  

Pretreatment Solutions: Filters & Housings

Smart water solutions to protect what matters

Shop our wide range of consumable filters and housings today. Pall Water's pretreatment solutions perfectly accompany existing Pall systems. Discover how effective filtration can protect your membranes, your systems, and your investments.