report on for treatment of wastewater for€¦ · based on these studies goldfinch prepared the...

REPORT

ON

FOR

TREATMENT OF WASTEWATER

FOR

I N D E X

SR. NO. C O N T E N T S PAGE NO.

1. INTRODUCTION 1

2. CHARACTERIZATION STUDY 2-4

3. TREATABILITY STUDIES 5-10

4. TREATMENT SCHEME 11-18

1

1. INTRODUCTION M/S Hikal Limited (Hikal) is situated in Mahad MIDC and mainly involved in the

manufacturing of Pesticides, insecticides & fungicides. Hikal is a reliable partner to

companies in the Pharmaceuticals, Biotech, Agrochemicals and Specialty Chemicals

industries.

HIKAL already have existing ETP (capacity 250 CMD) comprising of Primary, Secondary &

Tertiary Treatment to treat the waste water generated from the existing manufacturing

activities. Hikal is modernizing their existing manufacturing activities product due to which

there will be a change in the inlet characteristics of waste water. Hence the adequacy of

existing treatment system has to be worked out.

Hikal has appointed M/s Goldfinch Engineering Systems Private Limited(Goldfinch)

to carry out the characterization and treatability studies on the effluent samples to achieve

the parameters of treated waste water as per MPCB standards. Goldfinch has a well-

equipped laboratory accredited by Ministry of Environment and Forest (MoEF) certified by

ISO 9001:2008 and OHSAS 18001:2007.

To achieve this task Hikal provided the samples of waste water streams generated from

different processes to Goldfinch to carry out the characterization and treatability studies on

these samples.

Based on these studies Goldfinch prepared the report on treatability studies. This report is

organized as follows:

Section 2 deals with the characterization of waste water samples.

Section 3 details out the treatability studies and optimization of design parameters.

Section 4 mentions the treatment process along with the units and equipments required

with budgetary capital and operating cost estimates

2

2. WASTE WATER CHARACTERIZATION

The waste water samples from the manufacturing plant for each product under study were

collected by Hikal and sent to Goldfinch laboratory for studies.

These samples were characterized individually. These individual samples were analyzed for

pH, TDS, TSS, BOD and COD as they are deciding parameters for designing treatment

system. The results are mentioned below in table:

Sr

No Nature of Sample

Flow

(CMD) pH

COD

(mg/lit)

BOD

(mg/lit)

TSS

(mg/lit)

TDS

(mg/lit)

1 Ethyclozate 4.4 9.4 38429 16907 185 132436

2

MMPDC (5 Methoxy

methyl Pyridine

2 , 3 Dicarboxyalic acid)

16.5 8.4 39389 18118 135 85963

3 Diuron 21 2.6 37536 16887 168 118635

4 3,5 Dichloro Aniline 57.5 1.8 38528 18109 174 112635

5

APP (2 Amino 2 Methyl

isopropyloxy

6methyl propiophenone)

2 4.2 29182 13133 134 143673

6

AF 02 (4 acetoxy 6 tert

butyl 8 floro

2 3 dimethylequinoline)

9.3 9.4 52439 23586 128 112346

7 Benefuresate 5.7 10.2 36427 16394 143 153633

8 Benzofenap 2.62 5.3 31752 14285 189 136480

9 Clothianidin 0.3 1.2 8936 4291 142 13523

10 Azoxystrobin 2.8 7.6 4693 2253 124 12335

11 Thiacloprid 12.8 5.2 7354 3523 168 11023

12 SMPGM 0.4 3.6 9637 4627 167 10356

13 Fludioxanil 25.68 2.4 8639 4148 196 10524

Based on above, samples are divided in two groups

Group 1 High TDS stream (Product No. 1 to 8)

Group2 Low TDS stream (Product No. 9 to 13)

Group 1waste waterwill firstly be evaporated& its condensate will be mixed with Group 2 this

waste water. Composite sample was taken for treatability study.

3

For preparation ofGroup 1composite following samples were taken

Sr No Names Flow rates

(CMD)

Qty for composite

(ml)

1 Ethyclozate 4.4 148

2

5 Methoxy methyl Pyridine

2 , 3 Dicarboxyalic acid 16.5 554

3 Diuron 21 706

4 3,5 Dichloroaniline 57.5 1932

5

2 Amino 2 Methyl isopropyloxy

6 methyl propiophenone 2 67

6

4 acetoxy 6 tert butyl 8 floro

2 3 dimethylequinoline 9.3 312

7 Benefuresate 5.7 192

8 Benzophenaf 2.62 89

Total 119.02 4000

For preparation of Group2 composite following samples were taken


(CMD)

Qty for composite

(ml)

1 Clothianidin 0.3 28

2 Azoxystrobin 2.8 260

3 Thiacloprid 12.8 1192

4 SMPGM 0.4 37

5 Fludioxanil 25.68 2483

Total 41.98 4000

For preparation of total composite sample following samples taken


(CMD)

Qty for composite

(ml)

1 Stream 1 119.02 2217

2 Stream 2 41.98 783

Total 161 3000

4

Characterization of Group 1composite sample

Sr. No. Parameter Unit Value

1 pH -- 3.4

2 Chemical Oxygen Demand mg/lit 39146

3 BOD, 27oC for 3 days mg/lit 18028

4 Total Dissolved Solids mg/lit 113715

5 Total Suspended Solids mg/lit 143

6 Oil & Grease mg/lit 21

Characterization of Group 2 composite sample


1 pH -- 3.1





6 Oil & Grease mg/lit 33

5

3. Treatability Studies

As explained in the previous section, Hikal have proposed to reorganize the manufacturing

facility. This study was undertaken and aimed to treat the waste water to bring the

discharge to the standards prescribed by MPCB. The main objective of the treatability study

was to evaluate a feasible treatment process.

The day to day analysis and data logging were continuously monitored and recorded for

various treatment processes carried out in the laboratory.

For this, "Goldfinch" used lab model for all the studies at laboratory scale using composite

samples.

This section presents the results of the treatability studies.

Based on the characteristics of raw waste water, following treatment process was

considered for the treatability:

Evaporation

Primary treatment for coagulation and flocculation

Aerobic biological oxidation

Activated carbon adsorption

As BOD analysis requires three days while COD can be analyzed within 3 hours, COD was

used as a control parameter and the index of reduction in organic content during the

treatability study.

3.1 Evaporation:

Group 1 composite sample was neutralized and then subjected to distillation.Distillate was

collected and characterized. Analysis results were tabulated in Table 3.1

Table 3.1

Characterization of Wastewater after Evaporation (Condensate)


1 pH -- 7.2




Above condensate was mixed with Group2composite(Low TDS stream).This composite

sample was characterized.Results are as tabulated in table 3.2

6

Table 3.2

Characterization of Composite Sample (Group 1 condensate + Group 2)


1 pH -- 5.7




Above composite sample was taken for further study,

3.2 Primary Studies for Coagulation and Flocculation

Determination of Optimum pH

100 ml volume of wastewater samples after neutralization were taken in 4 cylinders. Alum

dose of 100 mg/lit was given to all the samples. The pH was adjusted to 7.0, 7.5, 8.0 and

8.5 respectively, by using 6N NaOH. After allowing for reaction time and settling, the

supernatant COD was checked. Satisfactory settling with best COD reduction was observed

at 7.5 PH. The results are presented in table 3.3.

Table 3.3

Determination of Optimum pH (Initial COD: 5513 mg/lit)

pH COD, mg/lit % Reduction in COD

7.0 4851 12

7.5 4686 15

8.0 4631 16

8.5 4603 16.5

On the basis of the above results, the optimum pH seems to be 7.5

Determination of Optimum Alum Dose

100 ml volume of wastewater samples were taken in 4 cylinders. Alum dose of 250, 500,

750 and 1000 mg/lit were given to respective wastewater samples. The pH was adjusted to

7.5 (optimum pH). After allowing for reaction time and settling, supernatant COD was

checked. Satisfactory settling with good COD reduction was observed for 500 mg/L alum

dose i.e. optimum dose. The results are presented in table 3.4.

7

Table 3.4

Determination of Optimum Alum Dose (Initial COD: 5513 mg/lit)

Alum Dose,

mg/lit

COD, mg/lit % Reduction in COD

250 4630 14

500 4305 22

750 4245 23

1000 4190 24

Note: Accordingly the optimum pH and optimum dose were seemed as 7.5 and 500

mg/lit respectively.

After primary treatment by alum supernant was analyzed for pH, COD, BOD3, TSS& TDS.

Results are tabulated in table 3.5

Table 3.5

Characterization of low TDS wastewater after primary Treatment

Sr.

No.

Parameter Unit Value

1 pH -- 7.2





6 Oil & Grease mg/lit <10

3.3 Secondary Treatment: Bio – degradation Study

After primary treatment waste water was subjected to biodegradation for secondary

treatment. For this 1000 ml. Bio sludge fromtheir existing ETP was taken. It was

settled. Supernant was removed.The sludge was washed 3 to 4 times with tap water.

This washed sludge was filtered, filtrate was discarded and the sludge was taken to

the 1000 ml beaker. It was mixed well and aerated for 10-15 min and the initial

sample was taken for COD.

COD of the bioreactor sample was checked and results are shown in table 3.6.

Initially the biomass was allowed to acclimatize with the effluent. The effluent after

primary treatment was diluted and fed to the bio-reactor. The studies were started

with 20% concentrated feed, which was steadily and subsequently increased by

40%, 60%, 80% and finally to 100%. Mixing and aeration were achieved through

diffused aeration system. Small quantity of sample were withdrawn and allowed to

8

settle for approximately 30min.Clear supernant was analyzed. Everyday loss of

water due to evaporation was made up with tap water.

Constant stirring was achieved throughout the experiment by aeration. After 100%

feed was achieved studies were formalized. Percent settlement of sludge was

observed after every 24 hrs. Also, COD was analyzed after every 24 hrs. Aftergiving

alum dose of 250 ppm at pH 7.5 to bioreactor sample. Result of Bio-degradation

study is summarized in the following table 3.6,

Table 3.6

Bio-degradation Study

Date Hours COD mg/lit

Initial 0 hrs 4605

06/02/2017 18 hrs 3228

07/02/2017 42 hrs 2218

08/02/2017 66 hrs 1488

09/02/2017 90 hrs 933

10/02/2017 114 hrs 693

11/02/2017 138 hrs 412

13/02/2017 186hrs 332

14/02/2017 210 hrs 314

Note:1. Lush brown healthy bio sludge was observed throughout the study.

Settling of bio-sludge was good and texture was characteristics.

From the above results it is seen that biodegradation was satisfactory.

Analysis of Bio-Degradable Sample

Sr.

No. Parameter Unit

Value

1 pH -- 7.1




6 Total Suspended Solids mg/lit <20

9

3.4 Tertiary Treatment (Activated Carbon Treatment)

Biodegraded sample was filtered and taken in 3 Nos. different beakers. A dose of

activated charcoal was given as 250, 500 and 750 mg/lit respectively. pH was

maintained at 7.5 Initial COD of the sample was 314mg/lit. All these mixtures were

stirred for one hour. After the reaction the mass was filtered and analyzed for

COD. The results are mentioned below.

Optimization of Charcoal Dose (Initial COD -314 mg/lit)

Charcoal Dose,

mg/lit COD mg/lit % reduction

250 266 15.3

500 162 48

750 112 35

Conclusion: COD is getting adsorbed on Charcoal. The optimum dose is 500 ppm.

Analysis of Tertiary Treated Sample

Recommended Treatment Process

High TDS stream generating from process separately to be evaporated in Multiple Effect

Evaporator (MEE) & condensate from MEE will be mixed with Low TDS stream & it will be

commonly treated in conventional ETP. For Primary treatment where its pH will be neutralized

& impurity like TSS, O&G will be removed. Primarily treated waste water will then be subjected

to biological oxidation or Secondary Treatment. After secondary treatment waste water will be

pumped to the tertiary treatment for removal of refractory COD. Consented 64 CMD will be

sent to CETP drain. Remaining (97 CMD) will be combined with cooling tower & boiler blow

down (34 CMD)& pass through Reverse Osmosis (RO). RO permeate will be used in cooling

Sr.

No. Parameter Unit

Value

1 pH -- 7.2




6 Total Suspended Solids mg/lit <20

10

tower & boiler. RO reject will be fed to evaporator; along with other high TDS stream (Group

1) salts from evaporator will send to CHWTSDF.

11

4. TREATMENT SCHEME Treatment with Multiple Effect Evaporators(MEE)

Filtered waste water along with RO reject will be pumped to MEE. MEE will be designed to

treat 200 CMD of waste water.

The feed to the evaporator will be collected in the feed tank and then pumped through the

preheaters to the 1st effect Evaporator calendria. The high pressure steam from the boiler

will be put in the TVR inlet. The TVR will suck the vapours from the 1st effect VLS and the

outlet of TVR will have steam at intermediate pressure and increased enthalpy. The outlet

steam from the TVR will be used as the heating medium for the 1st effect calendria. The

mass will then be recirculated in the Vapour Liquid Separator (VLS). The vapours separated

in the 1st effect VLS will be partly used as heating medium for the 2nd effect calendria and

partly will be sucked by the TVR. The vapours separated in the 2nd effect VLS will be used

for heating for the third effect calendria. . The vapours separated in the 3rd effect VLS will

be used for heating for the fourth effect calendria. The vapours separated in the 4th effect

VLS will be used for heating for the fifth effect calendria. The vapours separated in the 5th

effect VLS will be condensed in the condenser with cooled water and collected in the flash

pot. The steam or vapour in each effect will get condensed and get collected in the flash

pot. From the flash pot the condensate will be pumped to the condensate tank. The

concentrated feed in the 5th effect VLS will be pumped to the centrifuge for recovery of the

salt. The concentrate will be pumped back to 5th evaporator

Primary Treatment

The existing system will be upgrade & designed to treat 275 m3/day of wastewater. Waste

water Streams (Low TDS) will be pumped to bar screen chamber where bar screen will be

installed to screen out coarse solids particles like plastics, bottles etc. From the collection tank

the effluent will enter Oil & Grease Trap, where floating oil & grease is removed manually.

From Oil & grease trap the effluent will enter equalization tanks. The condensate from MEE will

also be mixed in these tanksThe equalization tank is provided with alkali dosing & acid dosing

arrangement for pH neutralization & coarse bubble diffuser will be provided to mix the waste

water. Alum and Poly will be dosed in the equalization tank itself. This effluent will be pumped

to Primary Settling tank. Suspended and coagulated solids get settled at the bottom of settling

tank which is pumped to dewatering system and clear supernatant will overflow into the

bioreactor.

12

Secondary treatment:

The existing system will be upgraded& designed to treat 275 m3/day of wastewater. The

primarily treated effluent will enter the bioreactor. In the bio reactor, dissolved organic

material is degraded by the micro–organisms present in the bio reactor. Oxygen required for

the oxidation of organic matter will be provided by means of diffuser aeration system which

will mix the contents of the bioreactor also. The mixed liquor will overflow into Secondary

Settling Tank (SST).

In the secondary settling tank, solid-liquid separation takes place and solids i.e. biomass will

settle at the bottom of the tank. Settled biomass will be recycled to the bio reactor for

maintaining the MLVSS concentration by using proposed sludge recycle pumps and excess

biomass will be wasted periodically to the sludge sump. The clear overflow from the Secondary

Settling Tank will be collected in the intermediate sump

Tertiary treatment:

The overflow effluent from Secondary Settling tank - II will enter the intermediate tank. The

effluent will be pumped through a pressure sand filter (PSF) for removing any fine solids

escaping the secondary settling tank & then through Activated Carbon filter for removal of

organics. The treated effluent will be collected in the final treated water tank from where it is

pumped to MIDC drainageleading toCETP up to 64CMD. Remaining will be sent to RO system.

RO System (RO)

Reverse Osmosis is at present a proven technology used to recover good quality water for

process use. The stream coming from the tertiary treatment will be passed through RO where

the dissolved solids are separated in the form of Reject & treated water free from dissolved

solids (Permeate - 166 CMD) is utilized for cooling tower and boiler feed. Reject of RO (55

CMD) shall be pumped to MEE.

Sludge Dewatering Unit

Primary sludge, excess biomass from the secondary treatment will be collected in sludge

collection tank and pumped to sludge drying beds. The solid cake will be disposed of to the

Government notified site. The filtrate water is directed back to equalization tank.

13

DESIGN PARAMETERS

A) ETP:

Parameters Unit Inlet

Effluent

After

Primary

Treatment

After

Secondary

Treatment

After

Tertiary

Treatment

Flow CMD 251 251 251 251

pH --- 4-5 7-7.5 7-7.5 7-7.5

COD mg/lit 5000-6000 4000-5000 300-400 <250

BOD mg/lit 2500-3000 2000-2500 10-20 <100

TDS mg/lit 2500-3000 3000-3500 1500-2000 <2100

Oil & Grease mg/lit 35-40 <10 <10 <10

Note: Out of 251 CMD 64 CMD will be discharge to CETP and remaining 187 CMD

will be fed to RO for further treatment.

B) RO

S.No. Parameters Unit Inlet Permeate Reject

1 Flow CMD 187+34 166 55

2 pH ---- 7 to 7.5 7 to 7.5 7 to 7.5

3 TDS mg/lit 1500-2000 < 100 9000-10000

C) Evaporator

Parameters Unit HTDS+RO

reject

Evaporator

Condensate

Quantity CMD 119+55 174+25

pH ---- 7.0 – 7.5 7.0 – 7.5

TDS mg/lit 85000-90000 100-500

COD mg/lit 39000-40000 4000-5000

14

UNITS AND EQUIPMENTS REQUIRED FOR EFFLUENT TREATMENT PLANT

A) ETP:

Sr. No Description

Size / Capacity

Qty. MOC Remarks Required

Volume

Existing

Volume

Additional

Volume

A) Civil Units & M.S Units List

1. Collection Tank 23 m3 10m3 13 m3 1 No AR – RCC Existing

&New

2. Equalization tank 46 m3 65m3 19 m3 1 No AR – RCC Existing &

New

3. Oil Separator 23 m3 35m3 -- 1 No AR – RCC Existing

4. Primary Settling Tank

(hopper bottom) 40 m3 27m3 13 m3 1 No FRP

Existing &

New

5. Bioreactor I 654 m3 75m3 579 m3 1 No RCC Existing &

New

6. Secondary Settling Tank I

(hopper bottom) 46 m3 10m3 36 m3 1 No RCC

Existing &

New

7. Bioreactor II 445 m3 75m3 370 m3 1 No RCC Existing &

New

8. Secondary Settling Tank II

(hopper bottom) 46 m3 10m3 36 m3 1 No RCC

Existing &

New

9. Bioreactor III 204 m3 200m3 4 m3 1 No RCC Existing &

New

10. Secondary Settling Tank

III (hopper bottom) 46 m3 32m3 14 m3 1 No RCC

Existing &

New

11. Final Treated Water Tank 275 m3 25m3 250 m3 1 No RCC Existing &

New

12. Sludge Drying Beds Suitable Suitable -- 3 Nos. RCC Existing &

New

13. Shed for Sludge Drying

Beds Suitable Suitable -- 1 No. MS-GI --

B) MS Fabricated, Mechanical & Bought out Equipment List

1. Air Blower for Bioreactor 922 m3/hr 1175m3/hr -- 2 Nos. CI Existing

2. Fine bubble diffuser 77 105 no -- Silicon Existing

3. Alum dosing tank for

Secondary 2750 lit 500 lit 2250 1 No. HDPE

Existing &

New

4. Sludge recirculation pump 12 m3/hr 10 m3/hr 2 m3/hr 2 Nos. CI Existing &

New

5. Instrumentation, piping

and Electrical Suitable Suitable Lot

Inst:

suitable

Piping:

MS/HDPE

Electrical

: suitable

Existing

19. PSF Feed pump 12 m3/hr @ 20 m

head

20 m3 / hr -- 2 Nos. CI Existing

20 Pressure sand filter (PSF) 1.23 m dia. x 1.5

m ht.

0.8 m dia.

x 1.5 m ht. 1 No. MS-Epoxy Existing

21 Activated Carbon filter 1.52 m dia. x 1.5 0.8 m dia. 1 No. MS-Epoxy Existing

15

(ACF) m ht. x 1.5 m ht.

22 Instrumentation, piping

and Electrical Suitable Suitable Lot

Inst:

suitable

Piping:

MS/HDPE

Electrical

: suitable

Existing

16

B) RO (Proposed) Design quantity: - 250 CMD

Sr.

No. Description Capacity/ Size MOC Qty.

A) Civil List

1 RO Feed Tank 250m3 CSGF 1 No.

2 RO Reject Holding Tank 55 m3 RCC 1 No.

3 RO Shed Suitable MS/GI 1 No.

4 Equipment Foundations As per requirement PCC Lot

B) Bought out & Fabricated Equipment’s

1 RO Feed Pump Suitable Duplex SS 2 Nos. (1W + 1S)

2 Acid Dosing Pump Suitable PP 1 No.

3 Acid Dosing Tank (with fume absorber) Suitable FRP 1 No.

4 Antiscalant Dosing Pump Suitable PP 1 No.

5 Antiscalant Dosing Tank Suitable FRP 1 No.

6 Agitator for Antiscalant dosing tank Suitable SS304 1 No.

7 SMBS Dosing Pump Suitable PP 1 No.

8 SMBS Dosing Tank Suitable FRP 1 No.

9 Agitator for SMBS dosing tank Suitable SS304 1 No.

10 Micron Cartridge Filter Suitable to 5 Micron

Housing :

Duplex

SS316

Cartridges :

Duplex

SS316

1 No.

11 High Pressure Pump Suitable Duplex SS 2 Nos. (1W + 1S)

12 RO membrane – fouling Water Suitable Thin Film

Polyamide

1 Lot

13 Pressure tubes for RO 5 Element Long FRP 1 Lot

14 RO Skid Suitable MS-FRP 1 No.

15 RO Permeate water tank 166 m3 SS304 1 No.

16 RO Permeate transfer Pump Suitable SS316 2 Nos. (1W + 1S)

CIP system for RO

17 CIP Tank Suitable HDPE 1 No.

18 CIP Pump Suitable SS 304 1 No.

19 RO Flushing Pump Suitable SS 304 1 No.

17

C) Evaporator (Proposed) Design quantity: - 200 CMD

Sr. No. Description Qty

Capacity

MOC Remark Volume req.

Existing Volume

1 Preheater – PHE 5 Nos. -- --

Tubes – SS – 316 Ti Liquid Contact parts – SS – 316 Shell – SS – 304

New

2 Evaporator Calendria

5 Nos. -- --

Tubes – SS – 316 Ti Liquid Contact parts – SS – 316 Shell – SS – 304

New

3 Vapour Separators 5 Nos. -- -- Liquid Contact parts – SS – 316

New

4 Recirculation Pumps

5 Nos. -- -- SS – 316 New

5 Thermo Vapour Recompressor (TVR)

1 Nos. -- -- SS – 304 New

6 Condensate pump 1 Nos. -- -- C.I New

7 Flash Pot 1 Nos. -- -- SS – 316 New

8 Surface Condenser 1 No. -- --

Tubes – SS – 304 Liquid Contact parts – SS – 304 Shell – SS – 304

New

9 Vacuum Pump 2 Nos. -- -- C.I New

10 Piping & Instrumentation

Lot Suitable -- SS / MS New

11 Electricals Lot Suitable -- -- New

12 Cooling Tower & Accessories

Lot Suitable -- FRP / MS New

18

Annexure-I ETP flow Diagr

report on for treatment of wastewater for€¦ · based on these studies goldfinch prepared the...

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