Journal - The Institution of Engineers, Malaysia  (Vol. 67, No.
1, March 2006) 57
SYSTEMATIC DESIGN OFA MAXIMUM WATER 
RECOVERY NETWORK FOR AN URBAN SYSTEM BASED 
ON PINCH ANALYSIS
S. R. Wan Alwi, Z. A. Manan and Z. Ujang    
Department of Chemical Engineering, Universiti Teknologi Malaysia 81310 UTM, Skudai, Johor
E-mail: zain@fkkksa.utm.my
1.0  INTRODUCTION
Water  demands  are  growing  every  year  as  the  result  of  the
booming world population. Apopulation report on environment
and water issues had estimated that more than 2.8 billion people
in  48  countries  will  lack  access  to  adequate  water  supplies  by
2025 [1].  The Middle-Eastern countries have long relied on non-
conventional water supplies due to water scarcity.  For example,
four Gulf states; Bahrain, Kuwait, Saudi Arabia, and the United
Arab Emirates have so little fresh water available that they resort
to  desalination,  a  costly  process  of  converting  sea  water  into
fresh water. Saudi Arabia now must mine fossil groundwater to
fulfill  three-quarters  of  its  water  needs.    Jordan  and  Yemen
withdraw  30%  more  water  from  groundwater  aquifers  every
year  than  the  replenishment  rate,  Israel's  annual  water  usage
already exceeds 15% of its renewable supply [2].
Huge investments have been spent to expand water supply to
increasing number of consumers in industry and housing estates
world-wide.    Rapid  increase  in  water  tariff  has  spurred  water
conservation efforts particularly in industrial sector.  It has been
reported that industrial water used in some developed countries
has  been  falling  as  a  result  of  greater  water  efficiency  through
reuse, recycling or regeneration of water. For example, industrial
water  use  in  England  and  Wales  has  fallen  by  900  million  m
3
since year 1998 [3]. While industries and commercial enterprises
have made significant progress in water efficiency, the reduction
of  water  usage  among  the  general  public  have  been  extremely
poor,  thereby  resulting  in  a  steady  increase  of  urban  water
demand [4]. This discrepancy can be attributed to the low water-
tariff  and  wide  availability  of  potable  water  in  urban  areas.
Consequently,  the  general  public,  particularly  the  urban
population, has little consciousness on water savings and hence,
the energy savings associated with water used. 
The  urban  sector  contributes  a  significant  percentage  of
water  consumption  particularly  in  developed  countries  with
warmer climates.  In Malaysia for example, the domestic sector
contributes  68%  of  the  total  water  consumption  compared  to
other sectors [5]. The need for efficient water management in
urban  sector  is  getting  more  crucial  as  a  result  of  the  sharp
increment of fresh water price.   This trend is likely to continue
in the near future due to the predicted shortage of fresh water,
and  hence,  the  possibilities  of  resorting  to  wastewater
treatment, desalination, groundwater extraction and, interstate
water  purchase  as  well  as  water  transfer.  Compared  to  the
extensive amount of work conducted on water minimisation in
industry,  there  has  been  much  less  efforts  towards  water
conservation in urban sector.
The  majority  of  works  on  urban  water  conservation  have
focussed on reuse of greywater with and without treatment and
rainwater harvesting.  Apart from the conventional approaches
of  water  recycling/reuse  and  rainwater  harvesting  for  lower
grade  water  usages  such  as  for  toilet  flushing  and  irrigation,
there  has  been  noteworthy  efforts  towards  maximising  water
recovery  through  the  design  of  closed-loop  water  system  as
well as water cascading. 
ABSTRACT
Pinch Analysis has been an established systematic technique for optimal design and retrofit of heat, mass and water recovery
networks in industry to achieve maximum energy as well as mass efficiency.  Until today, the application of Pinch Analysis is
perceived to exclusively belong to the domain of process industry.  This work represents a shift in the current process engineering
paradigm to allow Pinch Analysis application to be extended beyond the frontiers of process industry.  Two key developments
related to the extension of Pinch Analysis technique to the urban sector has been presented. One is as per the establishment of
the minimum water targets using the new water cascade analysis technique; and two, the adaptation of the source-sink mapping
technique for the design of a maximum water recovery network to an urban system to achieve the water targets.  
Application of these techniques on Sultan Ismail Mosque in Universiti Teknologi Malaysia yields potential maximum reductions
of 85.5% fresh water and 67.7% wastewater.
Keywords: Pinch Analysis, Regeneration, Urban Systems, Water Cascade Analysis
Figure 1: Aclosed water loop for a residential building [6]
057-064systematic design  6/22/06  4:44 PM  Page 57
Journal - The Institution of Engineers, Malaysia  (Vol. 67, No. 1, March 2006)
S.R. WAN ALWI, et al.
58
Closed  loop  water  system  aims  towards  a  total  re-use  of
all components in the wastewater. Bakir [6] has documented
the concept of closed loop in water demand management for
a residential building. The main idea is to match water quality
with the appropriate water usage as shown in Figure 1.  This
closed-loop  method  can  also  be  applied  for  household,
neighbourhood,  community,  industry,  or  institution  scale.
After  water  is  used,  the  generated  wastewater  is  segregated
into  greywater  and  blackwater  streams.  The  wastewater
streams  are  treated  accordingly  before  being  reused  or
recycled for other applications.
The  basic  principle  of  water  cascading  system  is  water
quality cascade where water sources are matched with end uses
in  terms  of  the  required  water  quality  as  shown  in  Table  1.
According to [7], water conservation can be maximised through
integration  of  the  whole  suite  of  water  conservation  measures
such as rainwater capture, installation of water efficient fixtures,
effluent  reuse  and  evaporation  as  well  as  productive  reuse  of
treated  effluent  in  roof  gardens.    Two  case  studies,  a  4-storey
commercial  green  building  in  Melbourne  and  a  typical
commercial  high-rise  building  have  shown  a  reduction  up  to
approximately  80%  of  freshwater  consumption  and  80%  of
wastewater discharge achievable via this technique. 
Toilet flushing contributes between 30 to 60 percent of water
uses  in  urban  areas  [8].   As  toilet  flushing  activity  is  one  of  the
highest  water  demands  in  urban  system  and  it  does  not  involve
human  contacts,  hence  the  reuse  of  greywater  after  treatment  or
rainwater for toilet flushing is a viable option with minimum health
risk [8, 9, 10, 11, 12]. Several researchers have reported significant
savings in reusing greywater and rainwater for toilet flushing.  For
example,  [13]  had  stated  that  theoretically  rain  or  greywater  can
replace all drinking water for toilet flushing.  This can constitute up
to 34% of the total water consumption.  Burkhard et al.[13] has also
reported that [14] study has managed to achieve a savings of 39%
and  sayers  [15]  has  reported  a  reduction  between  5.2  to  30.6%.
Aside  from  water  reuse  or  recycle  for  toilet  flushing,  its  use  for
irrigation is also an alternative. CSBE [16] reported that greywater
from  ablution  in  the  King  Abdullah  Mosque  in  Jordan  was
collected, filtered and reused for irrigation.  The system has resulted
in  significant  savings  on  the  mosques  water  bills  such  that  the
capital cost for installation of the system was recovered within the
first year of operation.
In  a  water  distribution  system,  it  is  possible  to  determine
the maximum water reuse/recycle flowrate through appropriate
water  cascading.    Note  that  the  maximum  water  reuse  and
recycling  corresponds  to  the  minimum  fresh  water
consumption.    The  first  key  step  towards  maximising  water
recovery  and  minimising  fresh  water  consumption  as  well  as
wastewater  generation  is  to  establish  the  baseline  minimum
water targets prior to the design of a water recovery network to
achieve  the  minimum  water  targets,  or  the  maximum  water
recovery (MWR) network.
The  available  works  on  water  targeting  and  MWR
network design are almost exclusively focused on industrial
applications, in line with the advent of Water Pinch Analysis
(WPA)  technique  [17,  18,  19,  21,  22,  23,  24].    Water  pinch
analysis  is  a  systematic  technique  for  implementing
strategies  to  maximise  water  reuse  and  recycling  through
integration  of  water-using  activities  or  processes.    Typical
WPA solution  comprises  of  two  steps,  i.e.,  setting  the
baseline water targets followed by network design to achieve
the baseline targets.  Wan Alwi et al. [25] had recently made
the first attempt to establish the baseline water targets for an
urban  water  system  using  a  new  technique  known  as  Water
Cascade Analysis (WCA).  
From the preceding review, it can be concluded that even
though  water  conservation  techniques  involving  reuse,
recycling and regeneration have been implemented for urban
system,  the  concepts  of  baseline  minimum  water  targets,
maximum water recovery design, stream mixing and process
modifications  to  achieve  the  minimum  water  targets  are
unknown for urban sector.  The objective of this study is to
extend  the  WPA methodology  beyond  the  frontiers  of
process industry for sustainability of water resources.  In this
work, the WPA technique will be used to design a maximum
water  recovery  network  for  the  urban  sector.    Breakthrough
of  WPA technique  into  the  urban  sector  will  significantly
contribute  towards  the  global  effort  for  efficient
conservation of water resources.
2.0  METHODOLOGY
Water management hierarchy consists of five levels, namely
(1) source elimination, (2) source reduction, (3) direct reuse/
outsourcing  of  external  water,  (4)  regeneration,  and  (5)  use
of  fresh  water  [26].  Water  Pinch  Analysis  (WPA)  is
concerned  with  maximising  water  reuse  and  regeneration-
reuse/recycling down the third and fourth level of the water
management  hierarchy.    This  will  minimise  fresh  water
consumption  as  well  as  wastewater  generation.    In  section
4.1  to  4.5,  this  study  presents  the  implementation  of  WPA
into  the  urban  system  in  five  key  steps.   The  first  step  is  to
Table 1: Water Quality Cascade with End Uses [7]
Figure 2: ZM Hierarchy of Water Management (Priority)
057-064systematic design  6/22/06  4:44 PM  Page 58
audit the existing or the base case water network in terms of
quantity  (flowrate)  as  well  as  quality  (contaminant
concentration). The second step is to identify and isolate the
relevant  water  sources  and  water  demands  having  potential
for  integration.  The  third  step  is  to  establish  the  minimum
water  and  wastewater  targets  using  the  water  cascade
analysis  technique  (WCA).  The  fourth  step  is  to  design  a
water  recovery  network  to  realise  the  minimum  water
targets.    The  final  step  is  to  consider  process  changes  like
regeneration  and  to  evaluate  the  economics  of  the  newly
designed  or  retrofitted  network.  A case  study  involving
Sultan  Ismail  Mosque  in  Universiti  Teknologi  Malaysia
(UTM) was used to illustrate the procedure for implementing
Water Pinch Analysis on an urban system.
3.0  RESULTS AND DISCUSSION
3.1 Audit of the existing Sultan Ismail Mosque
(SIM) water network
Sultan  Ismail  Mosque  (SIM)  located  in  Universiti  Teknologi
Malaysia (UTM) was chosen as the case study for this work to
illustrate the MWR network design method for urban system.
The four-storey mosque is mainly used by 3500 Muslim UTM
community  for  prayer  and  educational  activities.    The
estimated total fresh water consumption for SIM is 11550 m
3
/yr
[27].  Of this value, 9178 m
3
/yr is used for ablution and the rest
is  for  toilet  flushing,  irrigation,  mosque  cleaning,  wash-basin
and  toilet  pipes  [27].    The  total  water  consumption  varies
throughout the year during semesters and holidays.  During the
semester, the amount of water consumed for ablution is about
60 m
3
/day on Friday but only 25 m
3
/day on other days.  For this
study,  daily  water  consumption  calculations  will  be  based  on
normal  semester  days  [27].    Figure  3  shows  the  water  using
processes  in  terms  of  total  flowrate  and  limiting  maximum
contaminant  data.   The  initial  freshwater  consumption  for  the
mosque is 29.10 te/day.
3.2 Data extraction
The  maximum  limiting  contaminant  concentration  data  for
water demands for SIM was based on USA-EPA standards for
water reuse [28].  USA-EPA specifies for the BOD level to be
reduced  to  at  least  10  ppm  for  non-potable  domestic  water
recycle.  Non-potable water refers to water that is not used for
human consumption, such as for drinking.  Since all the water
usages  after  the  distribution  tank  in  SIM  was  non-potable,  a
maximum BOD limit of 10 ppm was set for the water demands.
A BOD  value  of  0  ppm  was  set  for  kitchen  water  demand.
Fresh water, greywater, rainwater, snow and treated wastewater
are  all  potential  water  sources.    The  limiting  contaminant
concentration for these water sources can be obtained via water
quality  test  or  from  literature  data.  "Blackwater"  from  toilet
flushing  and  toilet  pipes  were  not  considered  as  water  source
since  it  was  highly  contaminated  with  urine  and  faeces  while
water from irrigation was assumed to be completely absorbed
by soil.
The limiting data for water sources were based on the data
provided  [16]  as  well  as  from  [8].    CSBE    [16]  performed
quality  tests  on  ablution  greywater  collected  from  King
Abdullah  Mosque.    In  this  work,  it  was  assumed  that  wash
basin greywater and ablution greywater were of similar quality,
i.e.  23  ppm.  Surendran  and  Wheatley  [8]  conducted  research
on the average pollutant concentration in greywater from a hall
residence.  The BOD data for sources like showering, kitchen
and mosque cleaning for SIM were based on these data.  The
BOD for mosque cleaning was assumed to be similar to that of
a  washing  machine  since  they  both  contained  detergent.  The
limiting  data  for  the  water  demands  and  sources  are
summarised in Table 2 and 3 respectively.
3.3 Targeting the minimum utility using Water
Cascade Analysis technique (WCA)
One  of  the  latest  and  widely  used  water  targeting
techniques  known  as  water  surplus  diagram  [22]  is  limited  in
its  ability  to  estimate  the  minimum  water  targets  as  it
implements  a  graphical  approach  that  involves  time-
consuming trial-an-error steps.  This limitation has inspired the
development  of  a  numerical  technique  known  as  Water
Cascade  Analysis  (WCA)  that  eliminates  the  trial-an-error
approach [29].  The main objective of the WCA is to establish
the  minimum  water  targets,  i.e.  the  overall  fresh  water
requirement  and  wastewater  generation  for  a  process  after
looking at the possibility of using the available water sources
within a process to meet its water demands.
Manan et  al.  [29]  provides  a  detailed  description  of  how
WCAwas used to established the baseline water targets for the
Journal - The Institution of Engineers, Malaysia  (Vol. 67, No. 1, March 2006)
SYSTEMATIC DESIGN OFA MAXIMUM  WATER RECOVERY NETWORK FOR AN URBAN SYSTEM BASED ON PINCH ANALYSIS
59
Figure 3: Water distribution network for Sultan Ismail Mosque
Table 2: Summary of the water demands for Sultan Ismail Mosque
Table 3: Summary of the water sources available in 
Sultan Ismail Mosque
057-064systematic design  6/22/06  4:44 PM  Page 59
Sultan Ismail Mosque.  The targets generated via WCApredict
a  significant  potential  reduction  in  terms  of  fresh  water  and
wastewater,  far  beyond  the  water  network  revamp  proposed
earlier.  Table  4  shows  the  WCA targets  for  fresh  water
consumption  and  wastewater  generation  for  the  mosque  at
10.16  te/day  and  17.83  te/day  respectively.    These  targets
represent 65.1% fresh water savings and 51.5% of wastewater
reduction.  Note  that  the  pinch  point  for  the  mosque  water
network  exists  at  the  third  purity  level  (P =  0.999977)  where
there is zero cumulative pure water surplus.
Results of the study show that setting the minimum fresh water
and wastewater targets prior to design allow a designer to rapidly
pinpoint the options for water recovery network design that satisfy
the minimum water targets, thereby saving considerable amount of
resources in detailed evaluation and screening of numerous inferior
design options.  Next, a systematic procedure for the design of a
maximum  water  recovery  (MWR)  network  is  carried  out  to
achieve the baseline water targets established.
3.4 Design of a maximum water recovery
network
3.4.1 Network design 
The  network  that  achieved  maximum  water  recovery,  and
hence,  the  minimum  water  targets  without  regeneration  was
generated  using  the  source-sink  mapping  diagram  (Figure  4)
which  were  based  on  three  key  design  heuristics  presented  in
this section.  Table 4 shows the minimum fresh water target for
SIM at 10.16 te/day and the pinch concentration at 23 ppm. In
order to achieve the water targets, it was necessary to observe
the pinch division by designing the water networks above and
below the pinch separately according to heuristic 1:
Heuristic  1: Do  not  feed  water  sources  above  the  pinch
(including  fresh  water)  to  demands  below  the  pinch  and  vice
versa [22].
Heuristic  1  forbids  water  sources  above  the  pinch
(including fresh water) from being mixed with demands below
the  pinch  concentration.    On  the  other  hand,  it  also  disallows
mixing  of  demands  above  the  pinch  with  sources  below  the
pinch.  For the SIM case study, source S1 (10 ppm) above the
pinch  should  not  be  fed  to  any  demand  below  the  pinch
concentration.    However,  since  all  demands  in  this  case  were
above  the  pinch,  all  water  sources  above  the  pinch  could  be
matched with any of the demands.  Sources S4 (216 ppm), S5
(472  ppm)  and  S6  (536  ppm),  which  existed  below  the  pinch
should  not  be  fed  to  demands  above  the  pinch  according  to
heuristic  1.    Since  there  were  only  sources  and  no  demands
below the pinch, all sources there could not be reused and was
discharged as wastewater.  
Note  that  the  source  at  the  pinch  concentration  partly
belongs  to  the  region  above  the  pinch  and  partly  below  the
pinch.  The exact distribution of the source stream at the pinch
concentration is shown in column F
c
of the water cascade table.
Table  4  shows  that  7.8  te/day  of  water  source  at  23  ppm
belongs  to  the  region  above  the  pinch  while  17.37  te/day
belongs to the region below the pinch.
Heuristic  2  serves  as  a  guide  in  finding  the  right  match
between the various source and demand streams that exist in the
region above as well as below the pinch.  Following heuristic 2,
the  demand  at  the  lowest  contaminant  concentration  was  first
matched with the source at the lowest contaminant concentration.
Heuristic  2: Start  the  source-demand  matching  process  with
the demand at the lowest contaminant concentration [31]. 
For  the  SIM  case  study,  demands  D2  to  D8  existed  at  the
same concentration of 10  ppm.  Thus, the source at the lowest
concentration  could  be  matched  with  any  of  these  demands.
Table 4 shows that two sources can be selected to satisfy D2.
Source S1 at 10 ppm had the lowest contaminant concentration
and  was  first  selected  to  be  matched  with  demand  D2
according to heuristic 2.    
This  study  have  proposed  heuristic  3  as  a  corollary  to
heuristic 2 for the systematic mapping of the available source
streams  as  well  as  fresh  water  to  the  individual  demands.
Heuristic 3 and Equation (1) were used to determine the exact
contaminant load and flowrate of sources S1 and S2 to satisfy
demand D2. 
Heuristic 3: Map the available sources one after another, and
fresh water as required, to each demand according to heuristic
2 until all demands have been satisfied in terms of both quality
(contaminant load) and quantity (flowrate) .
The contaminant load of a source S or a demand D, (m
S/D
)
was calculated using Equation (1). 
(1)
Hence, the contaminant load of D2 (m
D2
) was obtained using
Equation  (1)  by  multiplying  its  flowrate  (F
D2
)  by  its
contaminant concentration (C
D2
).
Recall  that  S1  was  selected  to  satisfy  D2  according  to
heuristic 2.  The contaminant load of S1 was 0.11 kg/day. This
was less than the contaminant load required by D2.  Hence, all
11.14 te/day of S1 flowrate was used to satisfy D2.
m
S, i / D, j 
=
F
S/D
xC
S/D
1000
Journal - The Institution of Engineers, Malaysia  (Vol. 67, No. 1, March 2006)
S.R. WAN ALWI, et al.
60
Table 4: Water Cascade Table (WCT) for Sultan Ismail Mosque
case study
m
D2
=
F
D2
xC
D2
1000
m
D2
=
25.03te/dayx10ppm
1000
= 0.25kg/day
m
S1
=
F
S1
xC
S1
1000
m
S1
=
11.14te/dayx10ppm
1000
= 0.11kg/day
057-064systematic design  6/22/06  4:44 PM  Page 60
Journal - The Institution of Engineers, Malaysia  (Vol. 67, No. 1, March 2006)
SYSTEMATIC DESIGN OFA MAXIMUM  WATER RECOVERY NETWORK FOR AN URBAN SYSTEM BASED ON PINCH ANALYSIS
61
The  balance  of  D2  contaminant  mass  load  was  found  to  be 
0.14 kg/day
m
D2
= m
S1
+ m
S2
+ m
FW
m
S2
= 0.25kg / day - 0.11kg / day - 0kg / day = 0.14kg / day
The remaining contaminant load of 0.14 kg/day for D2 was
satisfied  using  source  S2  at  the  next  highest  contaminant
concentration.  The required flowrate of S2, determined using
Equation (2), was 6.04 te/day. 
(2)
However,  Equation  (3)  shows  that  the  total  quantity
required  by  D2  was  still  short  by  7.85  te/day  even  though  its
contaminant load had been satisfied.  The deficit of 7.85 te/day
was satisfied using fresh water according to heuristic 3.
F
D2
= F
S1
+ F
S2
+ F
FW
F
FW
= 25.03te/day - 11.14te/day - 6.04te/day = 7.85te/day (3)
The remaining quantity of 18.99 te/day from the total flow
of 25.03 te/day for source S2 was used to satisfy the demand at
the next highest contaminant concentration.
F
S2
= F
S2, D2
+ F
S2, left
F
S2, left
= 25.03te/day - 60.4te/day = 18.99te/day (4)
3.4.2 Network Modifications 
It  is  emphasised  that  Figure  4  is  only  one  of  the  possible
network  designs  for  this  case  study.    Other  possible  matches,
including  mixing  of  streams,  may  also  yield  the  maximum
water savings.  Even though WPAhad proposed a guideline for
design to achieve the maximum water savings, the decision to
strictly implement the design ultimately rests with the designer.
For  safety  or  layout  reasons,  a  designer  may  influence  the
network  design  by  imposing  forbidden  or  forced  connections
[22].  Adhering to these constraints may however incur penalty
in terms of the fresh water flowrate.
In  the  case  of  SIM,  accepting  the  proposed  network  in
Figure  4  will  require  rather  extensive  modifications  to  the
original network in terms of new pipeworks, storage tanks and
control system. The inconsistent ablution water flowrate would
have to be supplied to seven water demands. For each demand,
different  freshwater  flowrate  needed  to  be  added  in  order  to
satisfy  the  contaminant  balance.  This  may  be  uneconomical
and  difficult  to  implement.  Alternatively,  instead  of  piping
fresh  water  to  all  these  demands,  the  rainwater  (S1)  and
ablution  wastewater  (S2)  may  be  mixed  with  freshwater  in  a
distribution tank to produce a new water source at 10 ppm as
required.  With this modification, SIM was still able to achieve
maximum water savings.   The source and sink diagram for this
modified  design  and  the  flow  diagram  for  the  final  water
network is shown in Figures 5 and 6 respectively.  Note that the
water demands (D1 to D8) are ordered at the top according to
increasing  contaminant  concentration  from  left  to  right  while
the  water  sources  (S1  to  S6)  are  aligned  vertically  on  the  left
hand  side  according  to  increasing  contaminant  concentration
from top to bottom.
3.4.3 Water Regeneration Network Design 
Making  appropriate  changes  to  a  process  has  been  widely
accepted  as  an  effective  measure  to  further  reduce  utility
targets  in  heat  and  mass  integration  [18,  32].    The  same
principle  applies  to  WPA.      Two  possible  scopes  for  process
changes  to  further  reduce  the  water  targets,  and  hence,  water
F
S2
=
  m
S2
C
S2
F
S2
=
0.14kg.day
23ppm
x1000 = 6.04te/day
x1000
Figure 4: One possible water network design that achieved the
targets for SIM case (without regeneration)
Figure 5: Water network design that achieved the targets for SIM
case without regeneration (after modifications)
Figure 6: Final water network for SIM without regeneration
(freshwater savings: 65.1% and wastewater reductions: 51.5%)
057-064systematic design  6/22/06  4:44 PM  Page 61
Journal - The Institution of Engineers, Malaysia  (Vol. 67, No. 1, March 2006)
S.R. WAN ALWI, et al.
62
consumption,  include  water  regeneration  and  equipment
(hardware)  modifications.  Water  regeneration  involves  the
partial  or  total  upgrading  of  water  purity  using  purification
techniques  such  as  wastewater  treatment  like  microfiltration,
greenhouse filter, sand filter with reeds, multi media filter and
biofilter.  The regenerated water can either be reused in other
water-using  processes  or  recycled  to  the  same  process  to
further reduce water consumption and wastewater generation.
The main problem of dealing with process changes is that,
assessment  of  the  impact  of  changes  involves  repetitive
calculations to revise the utility targets and relocate the pinch.
Such  tasks  can  be  quite  cumbersome  in  the  absence  of  an
efficient  targeting  tool.   The WCA has  managed  to  overcome
this  problem  through  the  introduction  of  the  Water  Cascade
Table (WCT) that is very amenable to computer programming.
Recall that the pinch concentration for SIM case study was
23  ppm  (before  regeneration).  One  possible  option  of
regenerating the water source is to treat the ablution water to a
concentration  above  the  pinch.  It  was  suggested  that  7.27
ton/day of ablution water at 23 ppm be regenerated to 10 ppm
using sand filter with activated carbon.   Table 5 from the WCT
shows  the  new  pinch  purity  at  0.999977  (23  ppm),  and  the
fresh water and wastewater flowrates reduced to 6.06 ton/day
and  13.73  ton/day  respectively.  This  contributed  to  79.2%
freshwater  savings  and  62.7%  wastewater  reduction.  The
network design technique described previously also applies to
the case involving water regeneration. The final flow diagram
for  water  network  with  regeneration  that  achieves  the  new
water targets is shown in Figure 7.
3.4.4 Water Network Scheme for Sultan Ismail
Mosque Proposed by IEWRM 
The  Institute  of  Environmental  and  Water  Resource
Management  (IEWRM),  UTM,  had  proposed  a  water-
recycling  scheme  aimed  at  minimising  fresh  water
consumption for SIM. The retrofitted network design proposed
by IEWRM is shown in Figure 8.  IEWRM proposed the idea
of  reusing  treated  ablution  water  and  rainwater  for  the  entire
mosque  except  for  kitchen  services.    The  ablution  water  or
rainwater were to be filtered for solid particles like hair, stones
and  dirts  before  going  through  a  series  of  treatment  using
activated  carbon  and  sand  filter  processes.    The  treatment
process  was  to  ensure  that  water  being  recycled  to  the
distribution  tank  was  at  an  acceptable  purity  for  uses  which
involve body contact. 
The  amount  of  ablution  water  reclaimed  and  rainwater
collected was limited by the existing distribution tank.  Treated
ablution  water  will  only  be  sent  to  the  last  distribution  tank.
Since the water output was approximately 29.07 ton/day for the
four distribution tanks, only 7.27 ton/day of treated water can
be  fed  into  the  last  distribution  tank.    The  flowrate  of  7.27
ton/day  represented  the  limiting  point  or  bottleneck  for  this
system.    During  the  rainy  season,  rainwater  was  collected
instead and the spent ablution water was diverted to the sewer.
This  design  allowed  an  estimated  fresh  water  savings  and
wastewater reductions up to 25% and 20%, respectively. 
3.5 Economic Analysis 
The  system  proposed  by  IEWRM  predicted  fresh  water
savings of 25% and wastewater reductions of 19.8% (Figure 8).
The  system  suggested  by  WPA predicted  savings  of  79.2%
freshwater  and  62.7%  of  wastewater  reduction  after
regeneration (Figure 7).
Table  6  provides  a  preliminary  comparison  of  the
economics  between  the  solution  proposed  by  IEWRM  and
WPA involving  partial  water  regeneration.  Both  IEWRM  and
water pinch method used a UV disinfection unit and sand filter
with  activated  carbon  treatment  to  regenerate  about  the  same
amount  of  wastewater.    Sand  filter  equipped  with  activated
carbon that has a maximum flow rate flow of 7.27 m
3
/day costs
RM1170  per  unit  [33]  and  a  UV system  with  11  m
3
/day  flow
rate  cost  RM1900  per  unit  [34].    The  UV system  has  an
operating  cost  of  RM483  per  year  [34]  for  10  hours  in
operation per day per unit.  IEWRM uses one unit of sand filter
and UV system for their new water network solution while the
WPA solution  uses  one  unit  of  sand  filter  for  regeneration
(secondary treatment) purposes and two unit of UV system for
Table 5: WCT for process involving partial regeneration of
ablution water
Figure 7: Final water network for SIM after partial regeneration
(freshwater savings: 79.2% and wastewater reductions: 62.7%)
Figure 8: Retrofitted water network for SIM proposed by IWERM
057-064systematic design  6/22/06  4:44 PM  Page 62
Journal - The Institution of Engineers, Malaysia  (Vol. 67, No. 1, March 2006)
SYSTEMATIC DESIGN OFA MAXIMUM  WATER RECOVERY NETWORK FOR AN URBAN SYSTEM BASED ON PINCH ANALYSIS
63
primary treatment purposes.  The freshwater tariff in Johor for
the  year  2004  is  RM2.13  per  m
3
(SAJ  water  bill,  [35]).   This
gives  the  treatment  investment  cost  and  annual  freshwater
savings as stated in Table 6.  
Preliminary economic evaluation on these schemes indicated
the payback period for IEWRM and WPA at 7.4 months and 4
months,  respectively.    The  payback  period  using  WPA was
shorter  due  to  much  higher  potential  fresh  water  savings  as
compared  to  the  IEWRM  solution.  Note  however,  that  the
current analysis, which considered only the cost of regeneration
units  was  adequate  as  a  preliminary  economic  comparison  and
design  screening.    To  implement  the  selected  design,  a  more
detailed  economic  evaluation,  which  also  considers  pipework
and storage tank costs should be performed.
4.0 CONCLUSION 
A systematic  procedure  for  design  of  a  maximum  water
recovery network for an urban system based on WPAhas been
proposed.  Sultan Ismail Mosque was selected as a case study
to demonstrate the impact of the technique.  The conventional
solution proposed by IEWRM predicted fresh water savings of
25%  and  wastewater  reductions  of  19.8%.    However,  WPA
method  predicted  savings  of  65.1%  fresh  water  savings  and
51.5%  of  wastewater  reduction  for  SIM  without  regeneration
and 79.2% fresh water and 62.7% of wastewater reduction for
SIM  with  regeneration.    WPA enabled  the  minimum  utility
targets to be established prior to network design and provided
systematic  guidelines  for  the  design  of  an  MWR  network  to
achieve the established utility targets. 
I
REFERENCES
[1]  Hinrichsen D., Robey B., A. M., and Upadhyay U. D.,
1998, Population Reports (Volume XXVI, Number 1),
Center for Communication Programs, The Johns
Hopkins School of Public Health, USA.
[2]  McCarthy, M., 2003, Water Scarcity Could Affect
Billions: Is This the Biggest Crisis of All?, lndependent
UK.
[3]  Graham, N. J. D., 2001, Improving sustainability and
quality in urban drinking water supplies, URBAN
WATER, International Conference on Sustainable
Development and Green Entrerprises, MACAU G. E
[4]  Cheng, C., 2002, Study of the inter-relationship between
water use and energy conservation for a building,
Energy and Building, 34: 261-266, Elsevier.
[5]  The Malaysian Water Association, 2003, Malaysia
Water Industry Guide, 2003, Pg 74.
[6]  Bakir, H., 1999, Water demand management and
pollution control: Key to securing and safeguarding the
water supplies of MENA in the 21
st
Century,
http://www.emro.who.int [AssesedAssessed Februray
2004].
[7] Chanan, V., White, S., Howe, C., Jha, M., 2003,
Sustainable water management in commercial office
buildings, http://www.isf.uts.edu.au [Assessed  February
2004].
[8]  Surendran, S. and Wheatley, A. D., 1998, Grey-water
reclamation for non-potable re-use, Journal of
Chartered Instituition of Water and Environment
Management,12 (6): 406-413.
[9]  Hall, M. J., Hooper, B. D. and Postle, S. M., 1988,
Domestic per capita water consumption in South West
England, Journal Institution Water & Environment
Management, 2 (6): 626.
[10] Butler, D., 1996, How much water do we use? In Proc.
Of Conf. on Water Recycling  Technical and Social
Implications, The Instituition of Chemical Engineers,
London.
[11]  Edwards, K. and Martin, L. A., 1995, Amethodology for
surveying domestic water consumption, Journal
Institution Water & Environment Management, 9 (5): 477.
[12]  Kresig, D., 1991, Greywater recycling: Treatment
techniques and cost savings, Worlds Water and
Environment Engineering, 19 (2): 17.
[13]  Burkhard, R., Deletic, A. and Craig, A., 2000,
Techniques for water and wastewater management: a
review of techniques and their integration in planning,
Urban Water, 2: 197-221, Elsevier.
[14]  Sims, B., 1998, Liquid asset - services for housing grey
water recycling, Building Services Journal, p. 30.
[15]  Sayers, D., 1998, A study of domestic greywater
recycling, Interim Report. National Water Demand
Management Centre, Environment Agency. Worthing,
West Sussex.
[16] Center for the Study of the Build Environment (CSBE),
2003, A Report on Graywater Reuse in Jordan,
http://www.csbe.org [Assessed January 2004].
[17] Wang, Y. P. and Smith, R., 1994, Wastewater
Minimisation, Chem. Eng. Sci., 49, 9811006.
[18]  Linnhoff, B., Townsend, D. W., Boland, D., Hewitt, G.
F., Thomas, B. E. A., Guy, A. R., & Marshall, R. H.,
1982, A user guide on process integration for the
efficient use of energy, Rugby: IChemE.
Table 6: Economic comparison between the water network
schemes proposed by IEWRM and WPA (with regeneration)
057-064systematic design  6/22/06  4:44 PM  Page 63
Journal - The Institution of Engineers, Malaysia  (Vol. 67, No. 1, March 2006)
S.R. WAN ALWI, et al.
64
[19]  Dhole, V. R., Ramchandani, N., Tainsh, R. A.,
Wasilewski, M., 1996, Make Your Process Water Pay
For Itself,Chemical Engineering 103, 100-103.
[20] Sorin, M., & Bdard, S., 1999, The global pinch point
in water reuse networks, Transactions of IChemE,  Part
B. 77: 305-308.
[22]  Hallale, N., 2002, A new graphical targeting method for
water minimization, Advances in Environmental
Research, 6 (3): 377390.
[23]  El-Halwagi, M. M., Gabriel, F., & Harell, D., 2003,
Rigorous graphical targeting for resource conservation
via material recycle/ reuse networks, Ind. Eng. Chem.
Res., 42: 4319-4328.
[24]  Manan, Z. A., Ooi, B. L., Lim, F. Y., and  Foo, C. Y.,
2003, Heat-MATRIX - A Computer Software for the
Reduction of Energy and Water in Process Plants, 31
st
Int. Exhibition of Invention, New Techniques and
Products of Geneva, Switzerland.
[25]  Wan Alwi, S. R., Manan, Z. A., and Ujang, Z., 2004,
Systematic technique for water minimisation in urban
water system using water pinch analysis, Proceedings 
of ASIA WATER 2004, Kuala Lumpur, Malaysia.
[26]  Manan, Z. A. and Wan Alwi, 2005, A Holistic
Framework for Design of Minimum Water Utilisation
Networks for Industry and Urban Systems, AiChE
Journal, Under review.
[27]  Ujang, Z., and Larsen M., 2000, Development of Mass
Balance and Quantitative Inventory of Water
Management in UTM Skudai Campus for Reclamation
and Reuse Program, Research VOT 71498, Institute of
Environmental and Water Resource Management
Universiti Teknologi Malaysia, pg 33-35.
[28] Al-Jayousi, O. R., 2003, Greywater reuse: towards
sustainable water management, Desalination, 156: 
181-192, Elsevier.
[29]  Manan, Z. A., Foo, C. Y. and Tan, Y. L., 2004a, Targeting
the Minimum Water and Wastewater Flowrates using the
New Water Cascade Analysis Technique, AiChE Journal ,
Vol 50, No. 12, December 2004.
[30]  Manan, Z. A., Wan Alwi, S. R. and Ujang, Z., 2004b,
Water Pinch Analysis for Urban Systems: Setting the
Minimum Water Targets. Desalination (Ref: DES 3270)
[31]  Polley, G. T., and Polley, H. L., 2000, Design better
water networks, Chemical Engineering Progress, 96 (2):
47-52.
[32]  El-Halwagi, M. M., 1997, Pollution prevention through
process integration: systematic design tools. San Diego:
Academic Press.
[33] Delcol United Marketing (M) Sdn Bhd, 2004, e-catalogue,
www.delcolunited.com/ [Assessed  February 2004].
[34]  PuriTec, 2004, Advanced Air and Water Treatment
Technologies, www.puritec.com [Assessed Febuary
2004].
[35]  Syarikat Air Johor (SAJ) water bill, December 2004.
PROFILES
Zainuddin bin Abdul Manan
Chemical Engineering Department,
Universiti Teknologi Malaysia,
81310 Skudai, Johor, Malaysia.
NOMENCLATURE
Symbols
C =  contaminant concentration, ppm
F =  flowrate of water demand or source, kg/s or t/hr
n =  number of purity intervals
N =  number of water demands or sources
P =  purity
 =  difference
 =  summation
m = contaminant load
Subscripts
C = cumulative
D = water demands
FW =  fresh water
S = water sources
WW =  wastewater
057-064systematic design  6/22/06  4:44 PM  Page 64