REPORT ON TREATABILITY STUDIES, FEASIBILITY REPORT FOR ...environmentclearance.nic.in/.../EC/01042017OGDANQ0QTreatabiltyR… · REPORT ON TREATABILITY STUDIES, FEASIBILITY REPORT

REPORT

ON

TREATABILITY STUDIES, FEASIBILITY REPORT

FOR

TREATMENT OF WASTE WATER

FOR

M/s DEEPAK NITRITE LTD., MIDC Taloja

January -- 2017

PREPARED BY Goldfinch Engineering Systems Private Limited

Plot No. A -288, Road No. 16 Z, Thane Industrial Area, MIDC (Wagle Estate) Thane - 400 604 Maharashtra, India

TEL. 2580 15 29 FAX. 91 - 22 2583 1533 Website : www.goldfinchengg.com

I N D E X

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

1. INTRODUCTION 1

2. WASTE WATER 2 – 3

3. TREATABILITY STUDIES 4 – 6

4. TREATMENT SCHEME 7 – 12

Y:\Consultancy Services\EIA Reports\Current, In process\Deepak Nitrite Taloja\Tretability\report\Treatabilty Report without ZLD.doc 1

1. INTRODUCTION

M/s. DEEPAK NITRITE LTD. (DNL) is a leading supplier of organic, inorganic and fine chemicals to global

chemical majors. The DNL is a multi-division and multi-product company with manufacturing facilities at

Nandesari and Dahej in Gujarat, Taloja and Roha in Maharashtra, and at Hyderabad in Andhra Pradesh.

Wastewater is mainly generated due to production related activities.

DNL already have existing ETP comprising of Primary, Secondary & Tertiary Treatment to treat the waste

water generated from the existing manufacturing activities. DNL is changing their product mix due to

which there is a change in the inlet characteristics of waste water.

Hence DNL appointed M/s Goldfinch Engineering Systems Private Limited (Goldfinch), leading consultants

in the field of environmental engineering to carry out the treatability studies and devise a suitable

treatment process with its budgetary capital and operating cost estimates.

To achieve this task DNL provided the samples of waste water to Goldfinch. Goldfinch carried out the

treatability studies on these samples and arrived at the optimum treatment process, which is versatile in

operation. Based on these studies Goldfinch prepared the report on treatability studies and its optimum

treatment process. This report is organized as follows:

Section 2 deals with the characterization of waste water samples.

Section 3 details 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. WASTE WATER CHARACTERISTICS

The waste water streams are generated from the manufacturing processes which are concentrated

streams in terms of organic and TDS. These samples from the manufacturing plant were collected by DNL

and sent to Goldfinch laboratory for studies.

These samples were characterized individually. These samples were characterized for pH, COD, BOD3 270

C, chlorides and total dissolved solids (TDS). The average results are mentioned below

Table 2.1: Characterization of Streams

Sample No

Names Flow CMD

pH COD

(mg/lt) BOD

(mg/lt) TSS

(mg/lt) TDS

(mg/lt)

1 Toulidines (Ortho, Meta,

Para) 2 6.4 11800 5193 50 450

2

Xylidines(2,3/2,4/2,5/2,6/3,5

)OR Xylidiene Derivatives

as Xylenols(2,3/2,4/2,5/2,6)

3.7 5.9 6200 2790 36 436

3 Cumidines (Ortho, Para) 1.92 6.9 2205 1014 25 800

4 3 Amino Benzo Trifluoride

(3-ABTF) 1.6 7.1 8934 2705 56 664

5 Benzhydrol OR 3.97 6.4 6834 1743 34 837

6 Cyclohexenylethylamine

(CHEA) OR 22.5 7.8 10463 4074 89 654

7 Homoveratrylamine (HVA)

OR 0.26 7.3 1538 687 95 864

8 4-(2-Methoxyethyl)

Phenol.(4 MEP) 8.4 6.8 4231 1897 63 460

9 Boiler & Cooling Tower 27 7.4 22 4 48 680

Total 71.35 6.8 52227 20107 496 5845

The 4 Litres composite sample was prepared by mixing above samples in proportion of proposed flow

rates which were shared by M/s DNL. The Quantity of the samples are as mentioned in below table.


Table: 2.3Details of volumes for preparing Composite Stream

Sr No. Sample Name ML of Sample taken

1 Toulidines (Ortho, Meta, Para) 112

2 Xylidines(2,3/2,4/2,5/2,6/3,5)OR Xylidiene

Derivatives as Xylenols(2,3/2,4/2,5/2,6) 207

3 Cumidines (Ortho, Para) 107

4 3 Amino Benzo Trifluoride (3-ABTF) 90

5 Benzhydrol OR 222

6 Cyclohexenylethylamine (CHEA) OR 1262

7 Homoveratrylamine (HVA) OR 15

8 4-(2-Methoxyethyl) Phenol (4 MEP) 470

9 Boiler & Cooling Tower 1515

Total 4000

Characteristics of Composite

Sr. No. Parameter Unit Value

1 pH -- 7.7

2 Chemical Oxygen Demand mg/L 5103

3 BOD, 27oC for 3 days mg/L 1987

4 Total Dissolved Solids mg/L 639

5 Total Suspended Solids mg/L 61

6 Oil & Grease mg/L 18


3. TREATABILITY STUDIES

This study was undertaken to study the treatability of the effluent collectively and study the suitability of

the existing treatment process to meet the standards prescribed by MPCB of the old ETP and new ETP

individually including the adequacy of existing units and equipment, mainly for controlling the pH, COD,

BOD3 days, TDS & TSS values below the prescribed standard

Based on the characteristics of raw waste water, following treatment processes were considered for the

treatability:

Primary treatment comprising of neutralization and coagulation

Secondary treatment with Aerobic biological oxidation

Tertiary treatment with Activated carbon adsorption

For this Goldfinch tried physicochemical, biological unit processes at laboratory scale. In physicochemical

process, removal or conversion of contaminants to precipitate was brought about by dosing coagulative

chemicals. Aerobic biological oxidation was studied on primarily treated sample to remove biodegradable

organics while tertiary treatment was tried to remove refractory organics if any.

From the analysis of large number of samples collected, the BOD to COD ratio of raw waste water was

found to be about 50%. As BOD analysis requires three days while COD can be analyzed within 3 hours,

COD was used as control parameter and the index of reduction in organic content during the treatability

study.

3.1 Primary Treatment

3.1.1 Coagulation:

Determination of optimum pH and determination of optimum dose.

Coagulation is always highly effective only at particular pH with particular Alum dosage. Hence, studies

were carried out to determine optimum pH and dose. Methodology observed was as follows.


Determination of Optimum pH:

100 ml volume of wastewater samples were taken in 4 cylinders. Alum dose of 100 mg/lt 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 3.1.

Table 3.1 Determination of Optimum pH (Initial COD: 5103 mg/lit)

pH COD, mg/lt % Reduction in COD

7.0 4490 12

7.5 4337 15

8.0 4286 16

8.5 4261 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/lt 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 3.2.

Table 3.2 Determination of Optimum Alum Dose (Initial COD: 5103 mg/lit)

Alum Dose, mg/lt COD, mg/lt % Reduction in COD

250 4388 14

500 3980 22

750 3929 23

1000 3878 24

Note: Accordingly the optimum pH and optimum dose were decided 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 below


Table 3.3 Characterization of low TDS wastewater after primary Treatment


1 pH -- 7.2





6 Oil & Grease mg/L <10

3.3 Secondary Treatment: Bio – degradation Study

After mixing properly mixture was subjected to biodegradation for secondary treatment. 1000 ml mixture

sample was taken. MLSS was developed by adding 500 ml Bio sludge from efficiently operated ETP and it

was washed 3 to 4 times with tap water. This washed sludge was filtered, filtrate was discarded and the

sludge was added to the primarily treated composite sample. 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 below. Initially the biomass was

allowed to acclimatize with the effluent. The effluent 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 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. After giving alum dose of 250 ppm at pH 7.5 to bioreactor sample. Result of

Bio-degradation study is summarized in the following table 3.4.


Table 3.5 Bio-degradation Study

Date Hrs COD mg/lt

Initial 0 hrs 3878 02/01/2016 18 hrs 2520

03/01/2016 42 hrs 1688

04/01/2016 66 hrs 1215

05/01/2016 114 hrs 911

06/01/2016 138 hrs 710

07/01/2016 162 hrs 568

09/01/2016 210 hrs 472

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 very good.

Table 3.6 Analysis of Bio-Degradable Sample

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/lt respectively. pH was maintained at 7.5 Initial COD of the sample was 520

mg/l. All these mixtures were stirred for one hour. After the reaction the mass was filtered and analyzed

for COD. The results are mentioned below.

Table 3.7: Optimization of Charcoal Dose (Initial COD -472 mg/l)

Charcoal Dose, mg/lt COD mg/l % reduction

250 236 50 500 184 61 750 151 68


1 pH -- 7.1





7 Oil & Grease mg/L <10


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

Table 3.8: Analysis of Tertiary Treated Sample


1 PH -- 7

2 TSS mg/L 15

3 COD mg/L 184

4 BOD3,270C mg/L 75

5 TDS mg/L 334

3.5 Recommended Treatment Process

The waste water from process along with blow downs of cooling tower and boiler will be collected in the

equalization tank neutralized and will then pumped to Primary Settling Tank for settling the precipitated

solids. Alum will be dosed to settle the coagulated solids. The overflow of Primary Settling Tank will be

collected in the collection tank from where it pumped to secondary treatment. The secondary treated

wastewater will then be pumped for the tertiary treatment. The outlet of the tertiary treatment will be

pumped to CETP drain.


4. TREATMENT SCHEME

Primary Treatment

The streams will be collected in collection tank from where it pumped to neutralization tank where provision

of acid/ alkali dosing for neutralization of effluent will be made. The neutralizing agents will be dosed from

the respective dosing tanks. The content of equalization tank is mixed with help of coarse diffused aeration

system. The equalized and neutralized effluent will be then passed to flash mixer for primary clarification.

Alum will be dosed as coagulant in the flash mixer provided with agitator. The coagulated mass will flow to

primary settling tank for settlement of solids. The primary settling tank will be constructed with the hopper

bottom for effective removal of solids. The settled solids will be drained to the sludge collection tank. The

sludge from sludge tank is then pumped to the filter press for dewatering.

Secondary (Aerobic) Treatment:

The biological treatment will consist of following units;

The mixture from the tank will flow to the aeration tanks one after the other for the aerobic treatment.

Activated sludge treatment works on the principle of development of microbial culture in the aeration tank.

Each bacterium is constituted of C, H, N, O and P. Bacteria assimilate all carbonaceous matter. The oxygen

required for the bacterial growth will be supplied through the diffused aeration system. This system is energy

saving and effective as compared to surface aerator.

The mixed liquor suspended solids (MLSS) will continue to grow. The mixed liquor from the bioreactors will

overflow to the respective secondary settling tanks where the sludge will settle down and will be recycled to

the respective bioreactor to maintain the MLSS concentration. The clean treated effluent will overflow to the

intermediate sump.

TERTIARY TREATMENT

Tertiary treatment include following units;

The biologically treated effluent will flow to intermediate sump from where it is pumped to pressure sand

filter for removing any fine solids which have escaped settlement. The Filtered water will be passed through

the Activate charcoal Filter for polishing and removing any refractory organics. The tertiary treated effluent

will be fed to CETP drain.

Sludge Handling:

Primary sludge, excess biomass from the secondary treatment and backwash water from PSF will be collected

in the sludge sump. From the sludge sump the sludge will be pumped to the Filterpress for dewatering. The

solid cake from the Filterpress will be sent for disposal to Hazardous waste disposal site. The filtrate from the

Filterpress will be drained to the collection tank.


DESIGN PARAMETERS

A) ETP:

Parameters Unit Raw Stream After Primary

treatment After Secondary

Treatment After Tertiary

Treatment

Quantity M3/day 72 72 72 72

pH ---- 7-8 7-7.5 7-7.5 7-7.5

COD mg/L 5000-6000 4000-5000 300-400 150-250

BOD3, 270C mg/L 1500-2000 1500-2000 50-100 <100

TSS mg/L 50-100 <20 <20 <20

TDS mg/L 500-700 500-700 300-500 300-500

Oil & Grease mg/L <20 <10 <10 <10


UNITS AND EQUIPMENTS REQUIRED FOR EFFLUENT TREATMENT PLANT

A) ETP:

Sr. No Description Size / Capacity

Qty. MOC Remarks Actual Volume

Existing Volume

Additional Volume

A) Civil Units & M.S Units List

1. Collection Tank 10 10 -- 1 No AR – RCC Existing

2. Equalization tank 15 m3 65 -- 1 No AR – RCC Existing

3. Primary Settling Tank (hopper bottom)

13.13 m3 10 --

1 No FRP Existing

4. Bioreactor 240 400 -- 1 No RCC Existing

5. Secondary Settling Tank (hopper bottom)

12 12 --

1 No RCC Existing

6. Intermediate Tank -- 1 No HDPE Existing

7. Final Treated Water Tank 90 25 -- 1 No RCC Existing

8. Sludge Drying Beds 60 64 -- 4 Nos. RCC Existing

9. Shed for Sludge Drying Beds -- 1 No. MS-GI Existing

10. Equipment Foundations -- -- Lot RCC Existing

B) MS Fabricated, Mechanical & Bought out Equipment List

1. Coarse bubble Diffusers for equalization Tank

--

1 Lot PVC Existing

2. Primary Settling Tank Feed pumps

8 m3/hr 9 m3/hr --

2 Nos. CI Existing

3. Air Blower for Bioreactor 169.7 620m3/hr -- 2 Nos. CI Existing

4. Air Blower for Equalization 620m3/hr

5. Fine bubble diffuser 14 22 no -- Silicon Existing

6. Alum dosing tank for Secondary

25 25 lit --

1 No. HDPE Existing

7. Sludge recirculation pump 8 m3/hr 10 m3/hr -- 2 Nos. CI Existing

8. Instrumentation, piping and Electrical

Suitable Suitable

--

Lot

Inst: suitable Piping: MS/HDPE Electrical: suitable

Existing

19. PSF Feed pump 8 m3/hr 9 m3/hr -- 2 Nos. CI Existing

20 Pressure sand filter (PSF) 0.4 0.4 -- 1 No. MS-Epoxy Existing

21 Activated Carbon filter (ACF) 0.4 0.45 -- 1 No. MS-Epoxy Existing

22 Instrumentation, piping and Electrical

Suitable Suitable

--

Lot

Inst: suitable Piping: MS/HDPE Electrical: suitable

Existing


All other mechanical equipment’s such as pumps, blowers and other attended units exist with adequate

capacities.

Conclusion:

From the treatability studies treatment process scheme was derived from existing ETP which is operative.

Based on the parameters the required sizes of units were worked and were compared with existing units.

It is observed that existing units and equipment’s are quiet adequate.


ETP flow Diagram

Documents

REPORT ON TREATABILITY STUDIES, FEASIBILITY REPORT FOR ...environmentclearance.nic.in/.../EC/01042017OGDANQ0QTreatabiltyR… · REPORT ON TREATABILITY STUDIES, FEASIBILITY REPORT