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FAIRDEAL TEXTILE PARK PVT. LTD. Prepared by : EN‐PRO Enviro Tech And Engineers Pvt. Ltd.
Annexure – 8
Map Showing Proposed Green Belt Along With
Details Plan Of Greenbelt Development.
FAIRDEAL TEXTILE PARK PVT. LTD. Prepared by : EN‐PRO Enviro Tech And Engineers Pvt. Ltd.
Annexure – 9
Layout of Textile Park
FAIRDEAL TEXTILE PARK PVT. LTD.
Prepared by : EN‐PRO Enviro Tech And Engineers Pvt. Ltd.
Annexure – 10
Treatability Study On Industrial Effluent.
REPORT
ON
TREATABILITY STUDY CONDUCTED
ON WASTE WATER
FOR
M/S FAIRDEAL TEXTILE PARK Village: Mahuvej, Dist: Surat
By
Daystar Enviro Technologies Pvt. Ltd.
204-208, Silver Coin, Near Shrenik Char Rasta,
Akota, Vadodara - 390020
I N D E X
SR. NO. TITLE
0.0 EXECUTIVE SUMMARY
1.0 INTRODUCTION
2.0 AIM OF STUDY
3.0 SAMPLE COLLECTION
4.0 ANALYSIS OF WASTEWATER SAMPLES
5.0 TREATABILITY STUDY
6.0 PLAIN SETTLING
7.0 PHYSICO CHEMICAL TREATMENT
8.0 ACTIVATED SLUDGE PROCESS
9.0 TERTIARY TREATMENT
10.0 RESULTS & DISCUSSION
11.0 CONCLUSION
12.0 TABLES OF EXPERIMENTAL DATA
EXECUTIVE SUMMARY M/s Fairdeal Textile Park is being proposed as industrial infrastructure for industries such as
Yarn Texturising & Polyelectrolyte weaving units. A major portion of Textile Park shall be for
industries using Water Jet Looms.
The Textile Park being an upcoming project, wastewater samples were collected for carrying
out the treatability study, from existing industry having identical production unit set up.
The wastewater collected was allowed to settle for a period of 15 M to 2 hours, for removal
of free oil. The experiments indicated about 70% removal of free oil within 30 Min. The
wastewater was then subjected to physico chemical treatment using various chemicals like
FeSO4, FeCl3 & Alum. Different doses were triad and finally a dose of 200 mg/lit Alum & 2
mg/lit Polyelectrolyte provided good results; as indicated by COD reduction. The effluent
after physico chemical treatment was subjected to biological treatment in an Activated
Sludge Process.
Initially experiments were carried out as batch system keeping F/M ratio to 0.15 & MLSS
levels to 3000 mg/lit. The experiments were started using sewage sludge. After the
acclimatization period COD & BOD measurements were carried out. In the batch process it
was observed that good reduction of COD & BOD is achieved at hydraulic retention time of 8
hrs. After getting an idea from the batch a continuous aerobic system was run in the
laboratory for about three weeks.
The outlet samples were drawn and analyzed for parameters such as pH, COD, BOD, &
MLSS. It was observed that after stabilization the COD & BOD values of treated wastewater
were 15 mg/lit & less than 10 mg/lit.
The effluent after biological process was further treated by passing it through Graded Sand
Media & Activated Carbon column filter. This treatment had further reduced the COD & BOD
& the finally treated wastewater indicated COD of 10 mg/lit & BOD of less than 10 mg/lit;
which was as per the plant requirement of Reuse water.
The summary results of the treatability study are given in the report. Based on the treatability
study conceptual flow diagram of the proposed treatment facility is as given in enclosure-I.
Treatability study conducted for M/s Fairdeal Textile Park Village: Mahuvej, Dist: Surat 1.0. INTRODUCTION
Water is used as an important utility in operation of Water Jet Loom. The quality of
water is very important for smooth operation of the looms. As per the plant
specification the water used for Water Jet Looms shall have dissolved impurities
(Total dissolved salts) of less than 200 – 250 mg/lit & organic matter in negligible
concentration.
During the process of weaving of synthetic fabric using Water Jet Looms synthetic oil
(coning oil) applied to the synthetic threads is removed due to friction of water with
the fibre. The water used in Water Jet Looms is ultimately collected in the looms area
& is led to the collection sump. This water contains, soluble oil, free oil from
machines, small pieces of broken fibre & dirt, & is now termed as wastewater.
The wastewater when analyzed indicates pollutants, represented by COD, BOD, Oil
& Grease etc. & the higher value of the pollutants calls for its treatment.
Reuse of wastewater is an economical alternative to reduce fresh water use. To
establish the possibility of wastewater treatment & its reuse at the proposed Textile
Park a treatability study was carried out using wastewater from existing similar type
of industry.
2.0. AIM OF STUDY
Aim of the study was to achieve the treated wastewater quality as per reuse water
standards, indicated by the client; which is as given below.
Sr. No. Parameters Units Value
1 pH – 6.5 – 8.0
2 COD mg/lit < 30
3 BOD mg/lit < 10
4 Suspended Solids mg/lit < 10
5 Oil & Grease mg/lit < 10
6 TDS mg/lit 250
3.0. SAMPLE COLLECTION
To collect the samples and to understand wastewater generation locations, &
frequency a Textile unit using about 400 water Jet Looms, Near Kim was visited on
different dates. During the factory visit it was observed that wastewater is generated
at different times & at different flow rates. For this reason it was decided to collect
composite samples over a period of 24 hours. The samples were brought to
Laboratory and analyzed.
4.0. ANALYSIS OF WASTEWATER SAMPLES
The samples collected from the factory were analyzed for various parameters & the
analysis results are as given in Table No.: 1. The analysis reports indicated
comparatively constant value.
5.0. TREATABILITY STUDIES
The composite samples as received from the site were stored at 200C & used to
carry out the treatability study. Fresh samples were collected as and when required
for the treatability study.
6.0. PLAIN SETTLING
The wastewater indicates presence of free oil & hence sample was taken for plain
settling up to 2 hours. Settled sample was collected & analyzed for oil & grease. The
results are given in Table No.: 2.
7.0. PHYSICO CHEMICAL TREATMENT
The settled samples was subjected to chemical treatment; using FeSO4, FeCl3, Alum,
Polyelectrolyte. The results of above treatment are given in Table No.: 3.
8.0. ACTIVATED SLUDGE TREATMENT
The effluent after Alum + Polyelectrolyte treatment was subjected to Activated
Sludge Process. Initially a batch reactor was operated & subsequently a continuous
reactor was operated for a period of 3 weeks. During the trial MLSS in the reactor
was maintained at 3000 mg/lit. Required quantity of Nitrogen & phosphorus was
added in the reactor. Samples were collected at specified time intervals and analyzed
for COD & for a few sets for BOD. The results of Laboratory work are given in Table
No.: 4, 5 & 6.
9.0. TERTIARY TREATMENT
Activated Sludge Process outlet treated with Graded Sand Media Filter & Activated
Carbon. The results are as given in Table No.: 7 & 8.
10.0. RESULTS & DISCUSSION
Wastewater samples from existing textile unit was collected & analyzed to confirm
concentrations of various parameters. The treatability study was conducted on
composite samples collected & stored in Laboratory at 200C.
The wastewater was treated in below indicated treatment stages.
• Plain Settling
• Physico Chemical Treatment
• Activated Sludge Process
• Graded Sand Filtration
• Activated Carbon Filtration The plain settling have indicated good free oil removal capability and about 70% oil
reduction was observed in less than 30 minutes.
In the chemical treatment results were not encouraging with use of FeSO4, FeCl3 but
good results were obtained in using Alum with Polyelectrolyte. The wastewater after
chemical treatment showed good clarity & reduction of COD. The treated wastewater
after chemical treatment was subjected to biological treatment in on Activated Sludge
Process.
The processes of biological treatment have indicated vary encouraging results and
have provided COD / BOD reduction of more than 90%.
The treated wastewater was further treated by passing it through graded sand media
followed by Activated Carbon. The treatment had provided good reduction in
suspended solids & COD / BOD removal. During the treatment process the TDS
increase was very marginal as found by analyzing representative samples during
treatability period.
11.0. CONCLUSION
Form the above study it is clear that wastewater generated in proposed Textile Park
can very well treated applying physico-chemical, biological & polishing filtration
methods to achieve desired treated wastewater quality.
12.0. TABLES OF EXPERIMENTAL DATA
TABLE NO.: 1
Analysis of wastewater samples – January to February 2010
Sr. No.
Parameters
Colour pH TDS SS COD BOD Oil & Grease
1 Milky White 6.5 255 98 350 200 112
2 Milky White 6.0 200 160 290 190 96
3 Milky White 7.0 190 80 260 200 90
4 Milky White 6.6 150 100 310 230 130
5 Milky White 7.3 200 105 260 160 80
6 Milky White 6.8 160 110 300 190 160
TABLE NO.: 2
Primary Treatment (Plain Settling) Sr.
No.
Settling Time Oil & Grease (mg/lit) Suspended Solids (mg/lit)
Untreated After settling Untreated After settling
1 15 minutes 110 90 100 100
2 30 minutes 110 30 100 80
3 45 minutes 110 25 100 80
4 90 minutes 110 25 100 75
TABLE NO.: 3
Physico Chemical Treatment
Sr. No.
Treatment Dose (PPM)
pH COD TSS (mg/lit) (%) Redn. (mg/lit) (%) Redn.
Control Sample 7.0 280 – 100 –
1 Alum 50 6.5 210 25.0 90 10
100 6.5 150 46.4 50 50
200 6.4 140 50.0 40 60
2 FeCl3 20 6.0 250 10.7 90 10
100 5.5 230 17.8 90 10
200 5.0 210 25.0 80 20
3 FeSO4 50 7.0 240 14.3 85 15
100 7.0 230 17.8 80 20
200 7.0 200 28.6 80 20
Note: 2 mg/lit of polyelectrolyte was added in all above experiments.
TABLE NO.: 4
Activated Sludge Process (Batch Reactor) – 1st Set (with raw settled wastewater)
Sr. No.
Aeration Time (hrs.)
pH COD
BOD
mg/lit (%) Redn. mg/lit (%) Redn.
1 0 6.8 290 – 200 –
2 8 7.0 110 62 90 55
3 16 7.1 60 79 80 60
4 24 6.9 50 82.5 70 65
5 32 7.0 50 82.5 60 70
6 40 6.9 50 82.5 60 70
TABLE NO.: 5
Activated Sludge Process (Batch Reactor) – 2nd Set (with pretreated wastewater)
Sr. No.
Aeration Time (hrs.)
pH COD
BOD
mg/lit (%) Redn. mg/lit (%) Redn.
1 0 6.9 140 – 100 –
2 8 7.0 60 57.0 30 70
3 16 7.1 50 64.3 25 75
4 24 6.9 50 64.3 25 75
5 32 6.9 40 71.4 25 75
6 40 7.1 40 71.4 20 80
TABLE NO.: 6
Activated Sludge Process (Continuous Reactor)
Primary Treated Wastewater with Alum & Poly Treatment Feed Quality – pH – 7.0 COD – 160 BOD – 90
Sr. No.
Values % Reduces
Remarks
pH COD (mg/lit)
BOD (mg/lit)
COD
BOD
1 7.0 50 30 68.75 66.7 F/M = 0.15 2 6.8 50 – 68.75 – MLSS = 3000 mg/lit 3 7.0 50 – 68.75 – VSS = 2400 mg/lit 4 7.0 40 – 75 – 5 7.0 40 25 75 72.2 HRT = 8 hrs 6 7.0 40 – 75 – 7 7.0 40 – 75 – 8 6.7 50 – 68.75 – 9 6.9 60 30 62.5 66.7
10 6.9 50 – 68.75 – 11 7.0 40 – 75 – 12 7.0 40 – 75 – 13 7.0 40 20 75 77.7 14 6.8 30 – 81.2 – 15 6.8 40 – 75 – 16 7.0 30 – 81.2 – 17 7.0 30 15 81.2 83.3 18 6.9 20 – 87.5 – 19 6.9 15 – 90.6 – 20 6.8 15 – 90.6 – 21 6.9 15 10 90.6 91 22 6.8 15 – 90.6 – 23 6.9 15 – 90.6 – 24 6.9 15 – 90.6 – 25 9.9 15 10 90.0 91
Note: 1) Sludge settalability in the Aeration Tank was good.
2) Nutrients such as DAP & Urea was added once a week.
TABLE NO.: 7
Treatment of Activated Sludge Reactor Outlet with Sand Media Filter (1) Feed Quality
1) COD – 40 (mg/lit)
2) BOD – 15 (mg/lit)
3) Suspended Solids – 60 (mg/lit)
4) pH – 7 (2) Filter Column Details (Sand Media Filtration)
• Column Diameter – 25.4 mm
• Height of column – 1200 mm
• Filtration rate – 10 m3 / m2 / hr
• Filter Media – Graded Sand & Pebbles
Sr. No. Sampling Time (in minutes)
Filtrate Quality
Suspended Solids (mg/lit)
COD (mg/lit)
BOD (mg/lit)
pH
1 30 < 10 35 – – 2 60 (1 hr) < 10 35 – – 3 120 (2 hrs) < 10 35 – – 4 480 (8 hrs) < 10 30 – – 5 Composite sample < 10 35 15 7.0
TABLE NO.: 8
Treatment of Sand Media Filter Outlet with Activated Carbon Filter
(1) Feed Quality
5) COD – 35 (mg/lit)
6) BOD – 15 (mg/lit)
7) Suspended Solids – < 10 (mg/lit)
8) pH – 7 (2) Filter Column Details (Activated Carbon Filtration)
• Column Diameter – 25.4 mm
• Height of column – 1000 mm
• Filtration rate – 10 m3 / m2 / hr
• Filter Media – Activated Carbon with iodine value 800
Sr. No. Sampling Time (in minutes)
Filtrate Quality
Suspended Solids (mg/lit)
COD (mg/lit)
BOD (mg/lit)
pH
1 30 < 10 BDL – – 2 60 (1 hr) < 10 BDL – – 3 120 (2 hrs) < 10 BDL – – 4 480 (8 hrs) < 10 15 – – 5 Composite sample < 10 10 < 10 7.0
SUMMARY RESULTS OF TREATABILITY STUDY pH – 6.5 – 7.3 COD – 280
Raw Wastewater BOD – 210 TDS – 230 SS – 100 O&G – 110 After Plain Settling O&G – 30 (30 Mtrs) SS – 80 After Physico
Chemical Treatment pH – 6.9 Alum – 200 mg/lit COD – 140 mg/lit Poly – 2 mg/lit SS – 40 mg/lit After Activated pH – 6.9 Sludge Process COD – 15 mg/lit BOD – 10 mg/lit pH – 7.0 After Activated COD – 15 mg/lit Carbon Filtration BOD – < 5 mg/lit SS – < 10 mg/lit
Considering above treatability study CETP was designed, which comprises of following units. [A] Civil Units: Sr. No.
Description Size Nos. MOC Capacity m3
Residence Time
1 Inlet Chamber 4.2 M x 4.2 M x 2 MLD + FB 1 RCC 35 5 Min
2 Screen Chamber 8 M x 1 M x 1 MLD + FB 2 RCC 16 2 Min
3 Free Oil Removal Chamber 22.5 M L x 2.5 M x 2 M + FB 2 RCC 225 32 Min
4 Equalization Tank (3 Hrs. Holding Period)
22.5 M x 12.5 M x 2 MLD + FB 2 RCC 1125 2.7 Hrs
5 Flash Mixer Tank 3M x 3M x 1.2 MLD + 0.5 M FB 1 RCC 9 1.3 Min
6 Flocculator Tank 7.5 M x 7.5 M x 2.5 MLD + 0.5 M FB 1 RCC 140 20 Min
7 Primary Clarifier 21 M Dia x 3 MLD 1 RCC 1038.5 2.5 Hrs
8 Aeration Tank 30 M x 15 M x 4 MLD + 0.5 M FB 2 RCC 3600 8.5 Hrs
9 Secondary Clarifier 23 M Dia x 3 MLD + 0.5 M FB 2 RCC 2490 3.5 Hrs with recycle flow
10 Clarified Wastewater Tank (2 Hrs.) 17 M x 16.5M x 3 MLD + 0.5 M FB 1 RCC 841.5 2 Hrs
11 Treated Wastewater Tank (3 Hrs. cap.)
20 M x 20 M x 3.25 MLD + 0.5 M FB 1 RCC 1400 3.4 Hrs
12 Alum Solution Tank 1.5 M x 1.5 M x 1.2 MLD + 0.5 M FB 1+1 RCC 2.7 8 Hrs
13 Poly. Solution Tank (Pretreatment) 3 M x 2.5 M x 2 MLD + 0.5 M FB 1+1 RCC 15 8 Hrs
Sr. No.
Description Size Nos. MOC Capacity m3
Residence Time
14 Sludge Tank 5.5 M x 5 M x 2.5 MLD + 0.5 M FB 1 RCC 68.75 12 Hrs
15 Poly. Solution Tank (Centrifuge) 1.5 x 1.5 x 2 MLD +0.5M FB 1 RCC 4.5 –
16 Thickener Basin 6.5 M Dia x 2.5 MLD + 0.5 M FB 1 RCC – –
17 Thickened Sludge Tank 3.5 M x 3.5 M x 2.5 MLD + 0.5 M FB 1 RCC 30 –
18 MCC / Operating Room 18 M x 6 M x 4 M 1 RCC – –
19 Chemical Dosing Tank Area 10 M x 6 M x 4 M 1 RCC – –
20 Chemical Store 10 M x 6 M x 4 M 1 RCC – –
21 Centrifuge Shed 5 M x 8 M x 4 M 1 RCC – –
22 Sludge Shed 5 M x 10 M x 4 M 1 RCC – –
23 Centrate Sump 3.5 M x 3.5 M x 2 MLD + 0.5 M FB 1 RCC 24.5 –
[B] Mechanical Units: Sr. No.
Description Size Nos. MOC Remarks
1 Screen (Manual) 1 M Wide 2 MSEP –– 2 Oil Skimmers for Free Oil Reciprocating Type 2 SS / MSEP –– 3 Agitators 7.5 HP 4 MS / SS –– 4 Transfer Pumps 210 m3/hr x 1.5 kg/cm2 2+1 CI / CI –– 5 Flash Mixer (Mech.) 1.5 HP 1 MS –– 6 Flocculator (Mech.) 3 HP 1 MS –– 7 Primary clarifier Mechanism 21 M Dia x 3 MLD 1 MSEP –– 8 Air Blowers 2500 m3/hr x 0.55 kg/cm2 2+1 CI –– 9 Air Diffusers (Retrievable Type) 2 M Long 330 Silicon Rubber ––
10 Clarifier Mechanism 23 M Dia x 3 MLD 2 MSEP –– 11 Sludge Recycle Pumps 125 m3/hr x 1.5 kg/cm2 2+1 CI –– 12 Filter Feed Pumps 115 m3/hr x 2.5 kg/cm2 4+1 CI –– 13 Pressure Sand Filter 3.6 M Dia x 1.7 M Ht 4+1 MSEP –– 14 Activated Carbon Filter 3.6 M Dia x 1.8 M Ht 4+1 MSEP –– 15 Backwash Pump 200 m3/hr x 1.5 kg/cm2 1 CI –– 16 Backwash Blower 385 m3/hr x 0.15 kg/cm2 1 CI / CI Standby not required 17 Treated Wastewater Transfer Pump To be decided later - CI / CI These pumps shall be installed
as per requirement for transferring the treated wastewater to individual ind.
18 Agitator – Alum Soln. Tank 1.5 HP 1+1 SS-316 –– 19 Agitator – Poly. Soln. Tank 2.0 HP 1+1 SS-316 –– 20 Dosing Pump
AlumPoly
0-500 LPH x 4 kg/cm2 0-750 LPH x 4 kg/cm2
1+1 2+1
SS / PP SS / PP
––
21 Poly. Tank Agitator 1.0 HP 1 SS-316 –– 22 Poly. Dosing Pump (Centrifuge) 0-100 LPH x 4 kg/cm2 1+1 SS-316 –– 23 Thickener Feed Pump 4 m3/hr x 1.5 kg/cm2 1+1 CI ––
Sr. No.
Description Size Nos. MOC Remarks
24 Thickener Mechanism 6.7 M Dia x 2.5 MLD 1 MSEP –– 25 Centrifuge Feed Pump 2 m3/hr x 4 kg/cm2 1+1 CI / SS Screw Pump 26 Centrifuge Machine 2 m3/hr feed capacity 1+1 MS / SS –– 27 Pump Operating Panel As per requirement 1 MSEP –– 28 Interconnecting Piping As per requirement Lot MS / HDPE –– 29 Centrate Transfer Pump 10 m3/hr x 1.5 kg/cm2 1+1 CI To transfer Centrate to
receiving sump 30 Interconnecting Cables &
Accessories As per requirement 1 Lot – ––
31 Instruments a) Pressure Gauges b) Level Switch c) Flow Meter
Pump outlet & filter inlet outlet Equalization tank & clarified water tank Inlet of flash mixer & outlet of activated carbon filter
Lot
1 each
1 each
–
SS
SS / MS
–– ––
––
FAIRDEAL TEXTLE PARK PVT. LTD. Prepared by : EN‐PRO Enviro Tech And Engineers Pvt. Ltd.
Annexure – 11
SAMMATIPATRA Received from Plot
Owners
FAIRDEAL TEXTILE PARK PVT. LTD. Prepared by : EN‐PRO Enviro Tech And Engineers Pvt. Ltd.
Annexure – 12
Compliance report on CPCB Guidelines For
Management, Operation And Maintenance Of
Common Effluent Treatment Plants
FAIRDEAL TEXTILE PARK PVT. LTD. Prepared by : EN‐PRO Enviro Tech And Engineers Pvt. Ltd.
Sr. No.
Condition Compliance
1
Management System FTPL shall established management system for Membership to the CETP, Wastewater collection, Monitoring and performance of treatment units, manpower management and maintenance of CETP.
2
Membership to the CETP FTPL is Private Limited company. FTPL shall submit member list along with effluent load details to GPCB on regular basis. FTPL shall accept effluent only from valid member textile industries through underground pipeline. FTPL shall regularly monitor the effluent quality and quantity sent to CETP by visiting member industries. If any member found discharging effluent quality /quantity exceeding than prescribed norms they shall be charged with penalties.
3
Collection System FTPL shall lay down effluent conveyance pipeline of 10 MLD capacity, for conveyance of effluent from member industry to CETP. FTPL shall collect effluent sample from equalization tank of member industry on regular basis FTPL shall provide under ground collection sump to collect effluent from member industry followed by equalization tank.
4
Guidelines for operation of various units of CETP
FTPL shall provide effluent collection sump followed by Equalization tank of adequate size FTPL shall provide dosing tanks of treatment chemicals, flash mixer, and clariflocculator as primary treatment facility. FTPL shall provide aeration tank as biological treatment units. The details of CETP units along with capacity of each unit are given in Chapter -2, point 2.6.
FAIRDEAL TEXTILE PARK PVT. LTD. Prepared by : EN‐PRO Enviro Tech And Engineers Pvt. Ltd.
5 Manpower requirement FTPL shall provide well qualified staff for smooth operation of CETP.
6
Monitoring and Performance FTPL shall regularly monitor the effluent quality and quantity sent to CETP by visiting member industries. If any member found discharging effluent quality /quantity exceeding than prescribed norms they shall be charged with penalties and there effluent is not accepted by CETP until the quality and quantity is matched with prescribed norms.
7
Maintenance All pumps, mechanical devices, motors are regularly checked and greasing shall be done weekly. The break downs shall be attended immediately. And cause of the break downs shall be taken care permanently.
8 Trouble Shooting The operatory and chemists shall be given training for routine trouble shooting
FAIRDEAL TEXTILE PARK PVT. LTD. Prepared by : EN‐PRO Enviro Tech And Engineers Pvt. Ltd.
Annexure – 13
Drawings and Details
of Effluent Conveyance System
FAIRDEAL TEXTILE PARK PVT. LTD. Prepared by : EN‐PRO Enviro Tech And Engineers Pvt. Ltd.
Annexure – 14
Undertaking – Conducting audiography and not allowing dyeing
and printing units in FTPL