Industrial wastewater from soap and oil industries represents a heavy pollution source on their receiving water body. This paper studies a case of pollution control at Tanta Soap and Oil Company, Banha Factory, Egypt. The factory production includes soap, edible oil, and animal fodder. About 4,347 m3/day of industrial wastewater effluent was discharged via gravity sewers to the public sewerage system. Most of the effluent was cooling water because the cooling process in the factory was open circle. In spite of the huge quantity of cooling water being disposed of, disposal of wastewater was violating pertinent legislation. Three procedures were used for controlling the pollution at the Banha Factory. Firstly, all open circuit cooling systems were converted to closed circuit thus reducing the quantity of the discharged wastewater down to 767 m3/day. Secondly, the heavily polluted oil and grease (O&G) wastewater from the refinery unit is treated via two gravity oil separator (GOS) units, dissolved air floatation (DAF), and biological units in order to reduce the high levels of O&G, BOD, COD, and SS to the allowable limits. Thirdly, the heavily polluted waste effluent from the 'red water' saponification unit is treated separately by acidification to convert the emulsified fatty acid to free form in order to be separated through an oil separation unit. The effluent is then passed to liming stage to neutralize excess acidity and precipitate some of the dissolved matters. The mixture is finally clarified and the pH is adjusted to the allowable limits. The effluent wastewater from the three processes is collected and mixed in a final equalization tank for discharging effluent to the public sewerage system. The characteristics of the effluent water are very good with respect to the allowable Egyptian limits for discharging effluent to the public sewerage system.

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