Performance enhancement and hydraulic optimization of water treatment processes: A case study of Kafr El-Sheikh Water Purification Plant, Egypt

Access to clean drinking water remains a significant challenge in developing countries due to increasing demand. This study evaluates the efficiency of the Kafr El-Sheikh Water Purification Plant (KWPP). KWPP is a conventional plant without any advanced units. Hydraulic analysis revealed that the existing sedimentation tanks exceeded the allowable surface overflow rate (108 m³/m²/day) and weir loading rate (864 m³/m²/day), necessitating redesign in accordance with the Egyptian Code of Design Principles. The focus is on redesigning the plant to meet current and future water demands efficiently, with a phased expansion plan extending to 2062. Using the WatPro 4.0 water treatment process simulator, the study explores optimized chlorination strategies and advanced treatment technologies to minimize the formation of Disinfection byproducts (DBPs). The simulation examines adjustments to chlorine dosing based on influent water quality, integrating granular activated carbon (GAC) adsorption to remove organic matter, and applying ultrafiltration (UF) membrane technology to stabilize chlorine levels. The optimized approach successfully reduced the required initial chlorine dose to 2 mg/L and consistently maintained a chlorine residual of 2 mg/L, while maintaining THMs and HAA5s concentrations below 10 µg/L throughout the year. The findings highlight the importance of pre-treatment techniques in reducing DBP precursors before post-chlorination, ensuring safer drinking water . • Pre-treatment effectively reduces DBP precursors. • Safer drinking water was achieved post-chlorination. • WatPro simulation optimizes chlorine dosage. • GAC and UF reduce DBPs and help maintain chlorine stability.