recycle & reuse of water: bhairav desai, assistant engineer(drainage), surat municipal...
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SuratMunicipal Corporation
WASTE WATER RECOVERY&ENERGY GENERATION THROUGH SEWAGE GAS BASED POWER PLANT
Mr. Bhairav Desai Assistant Engineer – Drainage Department Surat Municipal Corporation
Location of Surat
Surat
• Surat dates back to 300 BC
• Municipality Established in 1852
• Municipal Corporation Formed in 1966
About Surat City
8th Largest in India as per population
4th fastest growing city globally
Termed as Economic Capital of Gujarat
9/10 Diamonds in the world are cut and polished here
40% of nations total man-made fabric & 28% of nation’s total man-made fiber production
Growth of City
Year Area in Sq. Km Population
1951 8.18 2,23,182
1961 8.18 2,88,026
1971 33.85 4,71,656
1981 55.56 7,76,583
1991 111.16 14,98,817
2001 112.27 24,33,785
2001* 326.51 28,77,241
2011 326.51 44,61,026
• Unprecedented growth in last four decades• Decadal Growth ~ 60-80%• 10-fold population rise• 10-fold area rise• City area expanded from
33.85 sqkm in 1971 to 326 sqkm in 2006
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Sewerage System
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Sewerage Scenario
Coverage : 167.50 sq.km. (i.e. 82 % of present
habitable area of @ 204 sq.km.)
Population catered : 97 % of present population
Length of sewer network : >1776 km
Nos of sewer manholes : > 65,000
Sewage Pumping Stations : 60 Nos (1986 MLD)
Sewage Treatment Plants : 11 Nos (982.5 MLD)
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Treatment Technologies Adopted
Sr.No.
Location of Treatment plant
Year of Commissioning
Capacity (MLD)
Process
1 Anjana 1995+2007 82.5 Conventional Activated Sludge
2 Bhesan 1995+2008 100 Conventional Activated Sludge
3 Bhatar 1999+2014 162 Conventional Activated Sludge+ SBR technology
4 Karanj 1999+2015 140 Conventional Activated Sludge+ Fixed film Technology
5 Singanpore 2003+2014 155 Conventional Activated Sludge + SBR technology
6 Bamroli 2002 100 UASB+ Extended Aeration
7 Asarma 2009 15 Moving Bed Bio Reactor
8 Khajod 2009 25 Moving Bed Bio Reactor
9 Variav-Kosad 2012 84 UASB+ Moving Bed Bio Reactor
10 Dindoli 2013 66 Conventional Activated Sludge
Grand Total 929.5
Sr.No.
Location of Treatment plant
Year of commissioning
Capacity (MLD)
Process
1 Anjana 1995 82.5 Conventional Activated Sludge
2 Bhesan 1995+2008 100 Conventional Activated Sludge
3 Bhatar 1999+2014 162 Conventional Activated Sludge+ SBR technology
4 Karanj 1999+2014 140 Conventional Activated Sludge+ Fixed film Technology
5 Singanpore 2003+2014 155 Conventional Activated Sludge + SBR technology
6 Bamroli 2002 100 UASB+ Extended Aeration
7 Asarma 2011 15 Moving Bed Bio Reactor
8 Khajod 2011 25 Moving Bed Bio Reactor
9 Variav-Kosad 2012 84 UASB+ Moving Bed Bio Reactor
10 Dindoli 2013 66 Conventional Activated Sludge
11 Gavier 2016 53 SBR Technology12 Grand Total 982.5
Sewage Treatment Plant
• Latest technology for Sewage treatment• MBBR (Moving Bed Bio Reactor) for STPs at Asharma & Khajod• UASB+MBBR (Up-flow Anaerobic Sludge Blanket + Moving Bed Bio
Reactor) treatment technology for Variav-Kosad STP• SBR (Sequential Batch Reactor) for STPs at Gavier, Siganpore and Bhatar• Fixed Film technology for Karanj STP• Use of Mechanical Dewatering System for Sludge Drying• Belt Filter Press• Centrifuge
Tertiary Sewage Treatment Plant
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Bamroli Sewage Treatment Plant
Single Stage Biological Treatment (2003)Two Stage Biological / Secondary Treatment (2008)Tertiary Treatment (2014)
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Bamroli Sewage Treatment Plant
Phase : I – Single Stage Biological Treatment
Capacity : 100 MLD Technology : Anaerobic Biological Treatment through UASB system. Year of Commissioning : 2003
Phase : II – Two Stage Biological / Secondary Treatment Capacity : 100 MLD Technology : Plant upgraded through Extended Aeration to meet the
revised stringent effluent discharge standards. Year of Commissioning : 2008
Phase : III - Tertiary Treatment Capacity : 40 MLD Product Water Technology : Ultra Filtration (UF) & Reverse Osmosis (RO) System. Year of Commissioning : 2014
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• Potable water demand is anticipated 2100 MLD by year 2025 as per master plan for projected Population.
• To meet huge water requirement due to industrial development, recycle and reuse of water is essential.
• Assured water requirement and assured revenue generation; enable guaranteed recovery of O&M cost by implementing such project on EPC basis.
• Revenue generation from recycled Waste water.
• Assured Water supply for Pandesara Industrial units.
Need of Waste Water Recycling Project
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Recycle, Reuse of Sewage Water Through Tertiary Treatment : Bamroli STP
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• Tertiary treatment of secondary treated sewage and to generate Industrial Grade Water for supply of Industrial Grade water to Pandesara Industrial Estate.
Tertiary Sewage Treatment Plant - Waste water Recycle - Reuse Project
PROJECT CONCEPT
OBJECTIVE Recycle / Reuse of waste water Contribution towards reducing the dependency on conventional
resources of water.
TECHNOLOGY
Sand Filtration Ultra-filtration (UF) Reverse Osmosis (RO) Activated Carbon Filter (ACF)
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Tertiary Sewage Treatment PlantCapacity of the plant : 40 MLD Contractor : M/s Enviro Control Associates (I) Pvt. LtdTechnology partner : M/s Hyflux, SingaporeCapital Project Cost : Rs. 85.10 croresPresent Fresh water cost to Industries : Rs. 23/KLRecycle water cost to Industries : Rs. 18.20/KL
(Yearly Increment on Indexation base)Project started -Commissined : August – 2012 / May - 2014Total ind. grade water supplied : 26,775 MLD (Till Oct-2016)Gross Income : Rs.50.92 Crore (Till Oct-2016)
Tertiary Treatment ProcessSecondary
Effluent
Ultra filtration
Reverse Osmosis
Pre- Chlorination
Post-Chlorination& pH adjustment
Flocculation
Product water Tank
To Pandesara Industrial
Estate
Activated Carbon Filter
Sand Filter
Disposal
Reject Water
57 MLD
8 MLD
Degasser System
Chemical Dosing
32 MLD
32 MLD
61 MLD
43 MLD
21 MLD
8 MLD
Partners & RolesSMC
• Conceptualization of project
• Preparation of detailed design, invitation of tender and selection of operating agency
• Project funding• Land allocation• Project execution• Payment of electricity
bill
GIDC - Pandesara
• End consumer• Assurance to purchase
committed quantity for well defined time duration
• Acceptance of the rate structure as mutually agreed
• Agreed to price variation corresponding to RBI index
• Regular payment to support the system
Contractor• Monitoring of inlet and
outlet parameters • Construction of plant to
meet the desired parameters
• Complete O&M of the plant including all major/minor repairs, replacements including spares
• Comprehensive treatment responsibility from collection point to disposal point
Parameters Inlet of TTP Outlet of TTPDesirable limits as per
Drinking water standard IS-10500
Color (Hazen units) 55 <5 5
pH 6.5-7.5 6-7.5 6-8.5
Total Hardness as CaCO3 (mg/L
750 <300 300
Iron as Fe(mg/L) 0.63 <0.25 0.30
Manganese as Mn (mg/L)
0.12 <0.10 0.10
Total Dissolved Solids (mg/L)
2100 <500 500
BOD (mg/L) 20 <5 No Standard
COD (mg/L) 100 <50 No Standard
Suspended Solids (mg/L) 30 <2 5.0 (Turbidity)
Total Nitrogen as N (mg/L)
14 <10 10.20
Total Phosphorous as P (mg/L)
8 6-10 -
Residual Chlorine (mg/L) 0.5 0.5 <0.25
Treated Water Quality Achieved TTP Inlet
TTP Outlet
Raw-TTP Inlet-TTP Outlet
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• Reject-water from Sand Filter, UF & RO is subjected to chemical treatment for reduction of Suspended Solids and BOD.
• The reject flow is pumped to the flash mixer and then to the flocculator.
• After flocculation, the reject flow is taken to the clarifier units. • The overflow from the clarifiers are connected to the existing
treated water disposal line of STP at the nearest point. Similarly the sludge is taken to Belt Filter Press system.
Major Treatment Units : Reject-Water Treatment
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• SMC was supplying 50-55 MLD potable water to Pandesara industries
• After introduction of tertiary water; supply is increased to 80-85 MLD.
• New network with separate water lines are installed for potable water and tertiary water in Pandesara industrial area.
• Tertiary water and potable water lines are separately color coded.
• Tertiary water is currently blended with fresh water up to 50% .
Tertiary Water Distribution Mechanism
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Project Financing & Payback# Financial Components Value
1 Capital Project Cost (including rehabilitation of water network)
Rs. 88 crores
2 O & M Cost (including electricity and 5% yrly. rise) for 18 years
Rs. 402 crore
3 Total inflow including Capex and Opex for 18 years 490 crore
4 Rate of Industrial Grade Water Rs. 18.20 per KL
5 Average rate of industrial water for 18 years Rs. 28.44 per KL
7 Total income for 18 years Rs. 747 crore
8 Payback Period 7 to 8 years
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• Reduced diversion of drinking water for non-potable purposes.• Conserve valuable ground water resources for future generation.• Facilitates recycling of wastewater - an environmentally sound and
progressive advance practice.• Assured resource for Pandesara Industrial Estate.• Enabled SMC to reduce pressure on conventional water resources in the
city.• Guaranteed revenue generation for Surat Municipal Corporation.
Tertiary Sewage Treatment Plant - Waste water Recycle - Reuse Project
BENIFITS
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• Seasonal variation in water requirement from industries.• Interrupted power supply for entire sewerage system and tertiary
system.• Mixing of Industrial Waste in to domestic sewage resulting to
disturbance of the plant performance.• Fluctuation in sewage quality, resulting in higher maintenance of
RO/UF ; consequently impact on life of RO.• Higher Sensitivity and complexity of system impact on tertiary
plant output.• Dependency on technology provider for trouble shooting.• Advance monitoring system for continuous monitoring of
incoming flow for non scheduled parameters is required. (i.e. Nano particles from textile industry)
Challenges
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• Interrupted power supply for entire sewerage system and Construction of Clarifloculator to control the inlet water quality to UF-RO system.
• Introduction of control techniques such as VFD and Equalization tank.
• Increase Tertiary treated water storage capacity in Plant.• Installation of express power feeder for uninterrupted power
supply.• Close and Continuous monitoring of Raw sewage / process
parameters.• Capacity Building of Staff.
Action Taken to meet the Challenges
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• Recycle & Reuse of Waste Water
• Augment Bamroli TTP from 40 MLD to 80 MLD.
• Tertiary treatment plant at Bhesan, Variav and Asharma for recycling of water for Hazira based industries, that may reduce water demand from Siganpore reservoir.
• Tertiary treatment plant at Dindoli and Bhatar for Sachin GIDC.
Replicability
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Future Plan – Towards zero discharge (2025)
Year Projected Sewage Collection (in MLD)
TTP Capacity(in MLD)
2016 860 402017 930 802018 1005 1532019 1080 2092020 1155 3592021 1210 4502022 1275 5602023 1345 7102024 1410 7702025 1470 825
SuratMunicipal Corporation
Sewage Gas Based Power Generation
Plant
• As an initiative towards Green Energy Generation from Sewerage; Sewage Gas Based Power Plant at STPs has been setup.
• Operational Biogas based power plant (6 Nos. - 4.625 MW)• Anjana : 0.5 MWe• Bhatar : 1.0 MWe• Karanj : 1.0 MWe• Singanpore : 1.0 MWe• Variav : 0.625 MWe• Bamroli : 0.5 MWe
• Till October- 2016, total Power generation from Bio gas based power plant is 5.35 crore KWH turned in to saving of Aapproximately Rs.25.78 Crore
Sustainable Initiative
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SYSTEM LAYOUT
• The Production of electricity through purely on sewage gas based engine generator technology have much more advantages and cost benefits over the earlier technology of duel fuel engine generator set.
• Power generation and utilization of it in sewage treatment plant reduce the electricity consumption of grid power.
• Saving in electricity bill will reduce revenue expenditure of Sewage treatment plant of SMC.
• Reduction of emission of green house gases for the protection of environment.
TECHNOLOGICAL REFORMS & BENEFITS
SURATMUNICIPAL
CORPORATION
Thank you