A REPORT

On

WASTEWATER MANAGEMENT

BY:

Nidhi Lashkari Shivani Agarwal

AT

Amol Pharmaceuticals Private Limited, Jaipur

ACKNOWLEDGEMENT
I would like to express my sincere gratitude to the chairman Mr. Ashok Luhadia, Managing director Mr. Sandeep Sapra, Vice President Mr. Girish Maheshwari, for giving me the opportunity to get training in Amol Pharmaceuticals Pvt. Ltd.

I am deeply indebted to Assistant Vice president (technical) Mr. SP Singh, who provides us the basic knowledge and gives us the necessary information about the report. I am highly grateful to them for his valuable guidance and sincere co-operation.

I hereby also thank the co-operation staff and workers of APPL for their whole hearted support.

ABSTRACT
The report is based upon all the knowledge that we have gathered at APPL about waste water management practices and how Amol Pharmaceuticals is working on the path of green environment. The report initially gives a brief introduction to Amol Pharmaceuticals Pvt. Ltd. and a basic introduction to pharmaceutical industry in general. It covers the different types of wastes which are generated in any pharmaceutical industry and the different processes which are used for their treatment.It then goes on to talk about the Effluent treatment Plant, biological treatment, water treatment plant and various processes used for the best possible use of water resource available. The report also gives an overview to various lab water grades and high efficiency purification systems used to achieve the specific water quality.

CONTENTS
1. 2. 3. 4. 5. INTRODUCTION TO APPL INTRODUCTION TO IIT ROORKEE INTRODUCTION TO PHARMACEUTICAL INDUSTRY WASTE CHARACTERISTICS AND THEIR TREATMENT EFFLUENT TREATMENT PLANT Introduction Equalisation Aeration Coaggulation and Flocculation Sedimentation Chlorination Dewatering Applications and Need 6. BIOLOGICAL TREATMENT 7. WATER TREATMENT PLANT Introduction Contaminants Multi Grade Filter Activated Carbon Filter Softener Reverse Osmosis Ion Exchanger Mixed Bed Ultraviolet Treatment Applications 8. HPLC GRADE WATER Overview of Lab Water Grades Type 1 water Applications

Introduction to Amol Pharmaceuticals Private Limited

Amol Pharmaceuticals Pvt. Ltd. (APPL) is a leading manufacturer of pharmaceuticals, herbals, minerals, vitamins, amino acids, specialty dietary supplements in the form of finished formulations. It was established as an India based manufacturer of pharmaceutical & nutraceutical products by Mr. Ashok Luhadia (in 1996). APPL & its group companies have grown to operate manufacturing facilities in the US, India & China and maintain two global sourcing offices, and an independent customer support & sales office for our US & world based clientele. The group has marched its way and has pedestalled its position as a leading manufacturer and exporter of Authentic Prodigious Pharmaceuticals and Neutraceuticals on Land. Its business model is to develop and supply customer specific pharmaceutical, herbal & nutraceutical products with an emphasis on quality control and customer service. Currently the portfolio of the companys products stretches well beyond 200 finished products, all manufactured in state of the art GMP certified production facilities ISO 9001-2000. The services offered by the company include analytical services as well as research and development services. The company also operates a Granulation and Testing Laboratory. Its principal administration and distribution facilities are based in the US, India & China with its Research & Development team imbedded across the three manufacturing units.

Mission & Vision

The mission of Amol Pharmaceuticals is to enhance the quality of life for humankind by providing innovative and trusted ingredients to the pharmaceutical and healthcare industry. They strive to be the best by meeting the technological and scientific needs or our industry, government and society.

Quality Objectives
Amol Pharmaceuticals Pvt. Ltd. is hereby commited to achieve the quality policy by: 1. Developing minimum five new products per year. 2. Ensuring that each & every dispatch meets quality satisfaction & delivery time. 3. Ensuring the production process are capable for consistently manufacturing the finished products of the required quality that comply with their specification and customer requirements

Quality Policy

M/s. Amol Pharmaceuticals Pvt. Ltd., Jaipur means complete customer satisfaction through Excellence in Quality and manufacturing quality products as per WHO standards. To achieve these standard they will: 1. Strong belief in quality and value added distribution services through a network of business association in order to increase market reach and penetration and thereby optimize economies of scale. 2. Make all employees aware of quality program of the company and educate them through training in current good manufacturing process (CGMP) and quality improvement techniques. 3. Achieving high standard of quality through continual improvement in processes and skill of the personnel.

Products
Tablets and Capsules Food and Dietary Supplements Herbals Minerals Amino Acids

Introduction to Indian Institute of Technology, Roorkee

Indian Institute of Technology - Roorkee is among the foremost of institutes of national importance in higher technological education and in engineering, basic and applied research. Since its establishment, the Institute has played a vital role in providing the technical manpower and know-how to the country and in pursuit of research. The Institute ranks amongst the best technological institutions in the world and has contributed to all sectors of technological development. It has also been considered a trendsetter in the area of education and research in the field of science, technology, and engineering. The Institute has completed 150th year of its existence in October 1996. On September 21, 2001, an Ordinance issued by the Government of India declared it as the nation's seventh Indian Institute of Technology. The Ordinance is now converted into an Act by the Parliament to make IIT, Roorkee as an "Institution of National Importance". The Institute offers Bachelor's Degree courses in 10 disciplines of Engineering and Architecture and Postgraduate's Degree in 55 disciplines of Engineering, Applied Science, Architecture and planning. The Institute has facility for doctoral work in all Departments and Research Centres. The Institute admits students to B.Tech. and B.Arch. courses through the Joint Entrance Examination (JEE) conducted at various centres all over India.

Introduction to Pharmaceutical Industry

The Pharmaceutical industry in India is the world's third-largest in terms of volume and stands 14th in terms of value. According to Department of Pharmaceuticals, Ministry of Chemicals and Fertilizers, the total turnover of India's pharmaceuticals industry between 2008 and September 2009 was US$21.04 billion, while the domestic market was worth US$12.26 billion.

The pharmaceutical industry includes the manufacture, extraction, processing, purification, and packaging of chemical materials to be used as medications for humans or animals. Pharmaceutical manufacturing is divided into two major stages: the production of the active ingredient or drug (primary processing, or manufacture) and secondary processing, the conversion of the active drugs into products suitable for administration.

The main pharmaceutical groups manufactured include: Proprietary ethical products or prescriptiononly medicines (POM), which are usually patented products General ethical products, which are basically standard prescription-only medicines made to a recognized formula that may be specified in standard industry reference books Over-the counter (OTC), or nonprescription, products.

The products are available as tablets, capsules, liquids (in the form of solutions, suspensions, emulsions, gels, or injectables), creams (usually oil-in-water emulsions), ointments (usually waterin-oil emulsions), and aerosols, which contain inhalable products or products suitable for external use. Propellants used in aerosols include chlorofluorocarbons (CFCs), which are being phased out. Recently, butane has been used as a propellant in externally applied products.

The major manufactured groups include: Antibiotics such as penicillin, streptomycin, tetracyclines, chloramphenicol, and antifungals Other synthetic drugs, including sulfa drugs, antituberculosis drugs, antileprotic drugs, analgesics, anesthetics, and antimalarials Vitamins Synthetic hormones Glandular products Drugs of vegetable origin such as quinine, strychnine and brucine, emetine, and digitalis glycosides Vaccines and sera Other pharmaceutical chemicals such as calcium gluconate, ferrous salts, nikethamide, glycerophosphates, chloral hydrate, saccharin, antihistamines (including meclozine, and buclozine), tranquilizers (including meprobamate and chloropromoazine), antifilarials, diethyl carbamazine citrate, and oral antidiabetics, including tolbutamide and chloropropamide Surgical sutures and dressings.

The principal manufacturing steps are Preparation of process intermediates; Introduction of functional groups; Coupling and esterification; Separation processes such as washing and stripping; and Purification of the final product.

Additional product preparation steps include granulation; drying; tablet pressing, printing, and coating; filling; and packaging. Each of these steps may generate air emissions, liquid effluents, and solid wastes.

The manufacture of pharmaceuticals is controlled by Good Management Practices (GMP) and an environmental assessment (EA) report addressing the fate and toxicity of drugs and their metabolized by-products.

Waste Characteristics and Treatment

Types of waste AIR EFFLUENTS The principal air pollutants are volatile organic compounds (VOCs) and particulate matter (PM). Air before entering the environment is treated by various air treatment systems to keep the environment pollution free. LIQUID EFFLUENTS Liquid effluents resulting from equipment cleaning after batch operation contain toxic organic residues. Their composition varies, depending on the product manufactured, the materials used in the process, and other process details. Cooling waters are normally recirculated.Spent Water in the labs and in varios production processes goes to the effluent treatment plant for treatment. SOLID EFFLUENTS The principal solid wastes of concern include process and effluent treatment sludges, spent catalysts, and container residues. Some solid wastes contain significant concentrations of spent solvents and other toxic organics. Solid waste is generally either incinerated or disposed in land fills or sent for treatment subject to the level of toxicity.

Effluent Treatment Plant

INTRODUCTION
Pharmaceutical industry produces a wide variety of products. This industries uses both inorganic and organic materials.The latter being either of synthetic or of vegetable and animal origin, some of the pharmaceuticals do not discharge liquid waste at all, some discharge very small but concentrated liquid waste, while some others discharge highly alkaline and toxic liquid wastes. Therefore it is very difficult to make any generation in regard to the characteristics of the pharmaceutical plant waste. Antibiotics and vitamins are produced by the fermentation of fairly complex nutrients of organic matter and inorganic salts, by fungi or bacteria.

The liquid waste from any antibiotic plant may be divided into the following groups
Spent liquor of the fermentation process. Wash water used for cleaning of floors and equipments. Waste containing acids, bases and solvents used for extraction and purification of the product. Filter aids used in the filteration, such as diatomaceous earth. Condensate from the barometric condensers in evaporation and drying under reduce pressure.

Design

EFFLUENT TREATMENT PLANT

Different processes in ETP Plant 1. Equalization

The wastewater produced by an industrial facility often varies in overall wastewater flow rate (e.g., as a result of day vs. night production processes) as well as concentration of pollutants (resulting from different types of operations being carried out at different times). Equalization is the operation aimed at eliminating or minimizing the problems associated with such fluctuations in wastewater flow and characteristics.

Equalization and Equalization Basins

The objective of equalization is to minimize or control fluctuations in those characteristics of the wastewater that may have an impact on subsequent treatments. Equalization is achieved by reducing the variations in flow rate and/or concentrations of the wastewater being fed to the treatment facility by using equalization basins.

Objectives of Equalization
Minimize fluctuations in flow rate to wastewater treatment plant. Reduce fluctuation in organic load or concentrations of pollutants to prevent shock loading of biological treatment system. Reduce fluctuation in wastewater pH. Minimize fluctuations in the amount of chemicals to be added to chemical treatment plant.

2. Aeration
Aeration is the process of bringing water and air into close contact in order to remove dissolved gases, such as carbon dioxide, and to oxidize dissolved metals such as iron. It can also be used to remove volatile organic chemicals (VOC) in the water. Aeration is often the first major process at the treatment plant. During aeration, constituents are removed or modified before they can interfere with the treatment processes.

How aeration removes or modifies constituents

In water treatment the aeration process brings water and air into close contact by exposing drops or thin sheets of water to the air or by introducing small bubbles of air and letting them rise through the water. For both procedures the processes by which the aeration accomplishes the desired results are the same: Sweeping or scrubbing action caused by the turbulence of water and air mixing together.

Oxidizing certain metals and gases .

Aeration can help remove certain dissolved gases and minerals through oxidation, the chemical combination of oxygen from the air with certain undesirable metals in the water. Once oxidized, these chemicals fall out of solution and become suspended material in the water. The suspended material can then be removed by filtration. Chemical substances affected by Aeration The constituents that are commonly affected by aeration are: Volatile organic chemicals, such as benzene, found in gasoline, or trichloroethylene, dichloroethylene, and perchloroethylene, examples of solvents are used in drycleaning or industrial processes. Carbon dioxide. Hydrogen sulphide. Methane. Iron. Manganese. Various chemicals causing taste and odor.

3. Coagulation and Flocculation

All waters, especially surface waters, contain both dissolved and suspended particles. Coagulation and flocculation processes are used to separate the suspended solids portion from the water. The suspended particles vary considerably in source, composition charge, particle size, shape, and density. The small particles are stabilized (kept in suspension) by the action of physical forces on the particles themselves. One of the forces playing a dominant role in stabilization results from the surface charge present on the particles. Most solids suspended in water possess a negative charge and, since they have the same type of surface charge, repel each other when they come close together. Therefore, they will remain in suspension rather than clump together and settle out of the water. Coagulation and flocculation occur in successive steps intended to overcome the forces stabilizing the suspended particles, allowing particle collision and growth of floc.

COAGULATION
The first step destabilizes the particles charges. Coagulants with charges opposite those of the suspended solids are added to the water to neutralize the negative charges on dispersed nonsettlable solids such as clay and color-producing organic substances. Once the charge is neutralized, the small suspended particles are capable of sticking together. A high-energy, rapid-mix to properly disperse the coagulant and promote particle collisions is needed to achieve good coagulation. Proper contact time in the rapid-mix chamber is typically 1 to 3 minutes.

Types of Coagulants
Chemical Name Aluminum sulfate (Alum) Ferrous sulphate Ferric sulphate Ferric chloride Cationic polymer Calcium hydroxide (Lime) Calcium oxide (Quicklime) Sodium aluminate Bentonite Calcium carbonate Sodium silicate Anionic polymer Nonionic polymer Chemical Formula Al2(SO4)3 14 H2O FeSO4 7 H2O Fe2(SO4)3 9 H2O FeCl3 6 H2O Various Ca(OH)2 CaO Na2Al2O4 Clay CaCO3 Na2SiO3 Various Various

Chemicals used at E.T.P. at APPL

Lime Alum

Dosing of Lime and Alum depends on the nature of water

FLOCCULATION
Following the first step of coagulation, a second process called flocculation occurs. Flocculation, a gentle mixing stage, increases the particle size from submicroscopic microfloc to visible suspended particles. The microflocs are brought into contact with each other through the process of slow mixing. Collisions of the microfloc particles cause them to bond to produce larger, visible flocs called pinflocs. Macroflocs are formed. Design contact times for flocculation range from 15 or 20 minutes to an hour or more. Once the floc has reached it optimum size and strength, the water is ready for the sedimentation process.

4. Sedimentation
Sedimentation, or clarification, is the process of letting suspended material settle by gravity. Suspended material may be particles, such as clay or silts, originally present in the source water. More commonly, suspended material or floc is created from material in the water and the chemical used in coagulation or in other treatment processes, such as lime softening. Sedimentation is accomplished by decreasing the velocity of the water being treated to a point below which the particles will no longer remain in suspension. When the velocity no longer supports the transport of the particles, gravity will remove them from the flow. The shape of the particle also affects its settling characteristics. A round particle, for example, will settle much more readily than a particle that has ragged or irregular edges. All particles tend to have a slight electrical charge. Particles with the same charge tend to repel each other. This repelling action keeps the particles from congregating into flocs and settling.

Sedimentation Basin Zones

Most sedimentation tanks are divided into these separate zones: Inlet zone The inlet or influent zone should provide a smooth transition from the flocculation zone and should distribute the flow uniformly across the inlet to the tank. Settling Zone

The settling zone is the largest portion of the sedimentation basin. This zone provides the calm area necessary for the suspended particles to settle. Sludge Zone The sludge zone, located at the bottom of the tank, provides a storage area for the sludge before it is removed for additional treatment or disposal. Outlet Zone The basin outlet zone or launder should provide a smooth transition from the sedimentation zone to the outlet from the tank.

Sedimentation Basin Shapes

There are many sedimentation basin shapes. They can be rectangular, circular, and square. Rectangular basins are commonly found in large-scale water treatment plants.

5. Chlorination(Disinfection)
Chlorination is the process of adding the element chlorine to water as a method of water purification to make it fit for human consumption. Water which has been treated with chlorine is effective in preventing the spread of waterborne disease. Chlorine is added to kill harmful (pathogenic or disease causing) organisms as the pathogenic bacterial organisms are somewhat less resistant to it. Sterilization is the complete destruction of all organisms in a water stream, which is not only unnecessary but it is also costly, and quite impractical. Disinfection of water with chlorine is rather a cheap and easier process.

There are three important operational factors involved in disinfection with chlorine. They are: The first is TIME/CONCENTRATION. These are two mutually related parameters. With long contact times, a low concentration of disinfectant suffices, whereas short contact times require higher concentrations to accomplish equivalent kills. The pH of the water has been shown to be a disinfectant factor also. A lower pH, which favors the formation of HOCL over OCLG, is more effective for disinfection. The final factor is that of temperature. The warmer the process water stream to be disinfected is, the faster the disinfecting action will be.

Dosage: The chlorine applied (or added) at the mixing point is called the dosage. It is usually expressed in terms of mg/l or lbs/day of chlorine that is added. The amount of chlorine added to the water coming from the clarifier is 2 ppm.

6. Dewatering
Dewatering is a physical unit operation aimed at reducing the moisture content of sludge. Sludge is not incinerated or land applied it must be dewatered or dried. This can be achieved by applying sand beds or by using mechanical dewatering equipment.

The selection of appropriate sludge dewatering technique depends upon Characteristics of the sludge to be dewatered Available space and Moisture content requirements of the sludge cake for ultimate disposal Dewatering may be improved by chemical conditioning, such as addition of a polymer. When land is available and sludge quantity is small, natural dewatering systems such as drying beds and drying lagoons are most attractive. Mechanical dewatering methods include vacuum filter, centrifuge, filter press and belt filter press systems. Sand drying beds are generally used as Sludge beds in conventional and medium sized plants. Sludge beds consist of bed of rocks, gravel, slag, peat moss, or plastic media. The moisture in sludge seeps down through various levels of the sludge beds and is then finally sent back to the equalisation tank for treatment. The sludge cake so formed after the dewatering process is disposed off.

Future Work
Initially the aerators used in the effluent treatment plant were diffused air aerators. Diffused aeration is also referred to as lake-bed aeration, bottom aeration, or destratification system. No matter what they are called, they operate in the same manner. Typical systems have an air compressor that has a tube that that connects to a diffuser located at the bottom of the pond or lake. As air is forced down the tubing, the diffuser breaks it up into tiny bubbles that are released into the

pond. The bubbling action of the air rising to the surface causing the water to de-stratify, meaning the poor, oxygen deprived water at the bottom of the lake is mixed with the oxygen rich water above, causing noxious and harmful gases to be released into the atmosphere. At the surface, where the bubbles break, additional oxygen transfer is made adding to the overall oxygen content of the water. Diffused aerators are best for ponds that are generally deeper than 8 feet, as their efficiency improves with deeper water. Diffused aerators can still be utilized in shallower ponds, however more units will be requiredand distributed evenly through out the pond, thus significantly adding to the overall cost. Their efficiency is derived from the micro bubbles that are being forced from the diffuser and floating to the surface. The deeper the water, the more destratification/ mixing the bubbles can do. They also offer the benefit of keeping electricity out of the water, since the air compressor is usually located on shore and only the air tubing enters the water.

Now, we have helped in the upgradation of the plant by installation of cascade or tray type aerators which further help in the removal of iron and other substances from the waste water. Cascade Aerator consists of a series of steps that the water flows over. In all cascade aerators, aeration is accomplished in the splash zones. The aeration action is similar to a flowing stream. Splash areas are created by placing blocks across the incline. Cascade aerators can be used to oxidize iron and to partially reduce dissolved gases. They are the oldest and most common type of aerators. Total height of the cascade may be between 1 and 6 meters. The large water surface thus created allows simple and fast aeration. Baffles obstructing the flow of the water increase the effect. The effectiveness of such a simple cascade depends on height between the upper surface of the water flowing over the weir and the surface of the water it falls on to. Effectiveness also depends on how uniform the water flowing over the weir forms a curtain. The effectiveness of a cascade can be increased by flow over several weirs in series. It follows that effectiveness depends on overall height of the cascade and therefore this governs the operating (energy) cost of the process. Cascade aeration is most likely to be encountered in treatment of surface waters before application of initial disinfection or application of coagulation.

Applications
Water from the clarifier tank after chlorine dosing is used in plantations by APPL. This water can also be used for human consumption after water purification process.

Need and Importance

Fresh water resources all over the world are threatened not only by over exploitation and Poor management but also by ecological degradation. Water pollution can be attributed to discharge of untreated waste, dumping of industrial efflurnts and runoff from agricultural fields, industrial growth, urbanization and increasing use of synthetic organics substances. This scenario requires efficient and effective treatment of water from such sources at reasonable cost before use to avoid instances of water borne diseases and to provide safe drinking water to the society.

BIOLOGICAL TREATMENT
Biologicaly degradable organics may exist in waste water in soluble, colloidal or suspended form. Biological removal of degradable organics involves a sequence of step including mass transfer, adsorption, absorption and biochemical enzymic reactions. An understanding of the microbiological metabolism and growth kinetics is there for necessary for a rational design of the biological treatment process.

Aerobic & anaerobic Before we go in to the discussion of various biological treatment processes, it is important to briefly describe the terms aerobic and anaerobic. Aerobic as the title suggests, means in the presence of air (oxygen) while anaerobic means in the absence of air (oxygen). These two terms are directly related to the types of bacteria or microorganisms that are involved in the degradation of organic impurities in a given waste water and the operating conditions of the bioreactor. Therefore, aerobic treatment processes take place in the presence of air and utilize those microorganisms (also called aerobes) which use molecular/free oxygen to assimilate organic impurities i.e. convert them in to carbon dioxide, water and biomass. The anaerobic treatment processes, on the other hand, take place in the absence of air by those microorganisms (also called anaerobes) which do not require air to assimilate organic impurities. The final products of organic assimilation in anaerobic treatment are methane and carban dioxide gas and biomass TYPES OF ACTIVATED SLUDGE SYSTEMS 1. Conventional Activated Sludge Process (ASP) System This the most common and oldest bio treatment process used to treat municipal and industrial waste water where specific concentration of biomass (measured as mixed liquor suspended solids (MLSS) or mixed liquor volatile suspended solids (MLVSS)) is maintained along with sufficien dissolved oxygen (DO) concentration (typically 2 mg/l) to effect biodegradation of soluble organic impurities measured as biochemical oxygen demand (BOD) or chemical Oxygen demand (COD). 2. Cyclic Activated Sludge System (CASS) Cyclic activated sludge system as the name suggests is one of the most popular sequencing batch reactor (SBR) processes employed to treat municipal wastewater and waste water from a variety of industries including refineries and petrochemical plants. 3. Intergrated Fixed Film Activated Sludge System (IFAS) There are several installations where two stage biological treatment comprising Stone or Plastic Media trickling filter (also known as packed bio tower) followed by activated sludge process based aeration tank followed by secondary claifier have been in operation.

4. Membrane Bioreactor (MBR) Membrane Bioreactor is the latest technology for biological degradation of soluble organic impurities. MBR technology has been in extensive usage for treatment of domestic sewage, but for industrial waste treatment applications, its use has been some what limited or selective.

Applications
Biological treatment is a very helpful tool in reducing the amount of sludge produced from the Effluent treatment plant.

WATER TREATMENT PLANT

INTRODUCTION
Water purity is extremely important to pharmaceutical and biochemical industries. Suspended or dissolved particles, organic compounds, impurities and other contaminants prohibit the usage of tap water in laboratory applications and scientific research. Parameters such as resistivity, conductivity, size of particulate matter and concentration of microorganisms are used to categorize water quality and, therefore, specify intended uses for water. Some applications can tolerate the presence of specific impurities in the water, but others, such as High Performance Liquid Chromatography (HPLC) require removal of the majority of contaminants.

Contaminants
Water is an excellent solvent and can be sourced from almost anywhere on Earth. This property makes it prone to all kinds of contamination. Particulates: Silt and debris which can be removed by passing water through a 10 to 20 micron filter (or less if necessary). Microorganisms: Bacterial agents constitute a real challenge for water purification systems. Their growth rate, size and robustness require an efficient design (detection, removal from water inlet, inhibition of growth, etc.). Bacteria are measured in colony forming units per milliliter and can be killed with disinfectants. As a result, their secretions and cellular fragments must also be removed to avoid contamination. Endotoxins, pyrogens, DNA and RNA: Cellular fragments and bacterial by-products. Harmful to tissue cultures. Can be detected with a Limus Amoebocyte Lysate (LAL) test. Dissolved inorganic elements: Include phosphates, nitrates, calcium and magnesium, carbon dioxide, silicates, iron, chloride, fluoride, and any other natural or man-made chemicals resulting from exposure to the environment. Electrical conductivity (Siemens/cm) is used to monitor high concentration of ions, while resistivity (Mcm) is used to identify ions if present in small concentrations. These contaminants affect water hardness and alkalinity/acidity. Dissolved organic elements: Pesticides, plant and animal remains or fragments. Total Organic Carbon (TOC) analyzers are used to measure CO2 emitted by organics subjected to oxidization. Organic-free water is mainly used in applications where analysis of organic substances is carried out (e.g. HPLC, chromatography and mass spectrometry).

Scientific applications require elimination of certain types of contaminants. On the other hand, pharmaceutical productions require, in most cases, near-total removal of impurities (criteria dictated by specific standards or local/international regulatory bodies).

Purification Process
Water purification is the process of removing undesirable chemicals, biological contaminants, suspended solids and gases from contaminated water. The goal is to produce water fit for a specific purpose. Most water is purified for human consumption (drinking water) but water purification may also be designed for a variety of other purposes, including meeting the requirements of medical, pharmacological, chemical and industrial applications. In general the methods used include physical processes such as filtration, sedimentation, and distillation, biological processes such as slow sand filters or biologically active carbon, chemical processes such as flocculation and chlorination and the use of electromagnetic radiation such as ultraviolet light. The purification process of water may reduce the concentration of particulate matter including suspended particles, parasites, bacteria, algae, viruses, fungi; and a range of dissolved and particulate material derived from the surfaces that water may have made contact with after falling as rain.

Design

WATER TREATMENT PLANT DESIGN AT APPL

COMPONENTS

1. Multi Grade Filter

Multigrade filter is a depth filter that makes use of coarse and fine media mixed together in a fixed proportion. This arrangement produces a filter bed with adequate pore dimensions for retaining both large and small suspended particles. This filter performs at a substantially higher specific flow rate than conventional filters. Specific flow rates of 0.82 1.64 ft/min have been successfully obtained for treating waters containing 25 50 ppm suspended solids respectively to produce filtrate with less than 5 ppm. Multigrade filter finds applications in side stream filtration of cooling water and in potable water treatment. It is ideal for filtration of clarified water. In addition it finds application in sea water filtration and in filtration of chemical solutions.

MULTI GRADE FILTER

2. Activated Carbon Filter

Activated carbon (AC) is generally used in water treatment for removing free chlorine and / or organic compounds. Removal of organics from potable water could be to prevent common organic acids such as humic or fulvic from reacting with chlorine to form trihalomethanes (a class of known carcinogens) or, to treat waste water to remove any number of organic compounds to make the water suitable for discharge. This not only improves taste and minimizes health hazards. It protects other water treatment units such as reverse osmosis membranes and ion exchange resins from possible damage due to oxidation or organic fouling. Activated carbon is a favored water treatment technique because of its multifunctional nature in the fact that it adds nothing detrimental to the treated water. Most Activated carbons are made from raw materials such as nutshells, wood, coal, and petroleum. Typical surface area for activated carbon is approximately 1000 m2/g .

The two principle mechanisms by which activated carbon removes contaminants from water are adsorption and catalytic reduction. Organics are removed by adsorption and Residual Disinfectants are removed by catalytic reduction.

ACTIVATED CARBON FILTER DESIGN

3. Water Softener
Water softening is the reduction of the concentration of calcium, magnesium, and certain other metal cations in hard water. These "hardness ions" can cause a variety of undesired effects including interfering with the action of soaps, the build up of limescale, which can foul plumbing, and galvanic corrosion. A water softener is an ion exchanger where hard waterwater with a high calcium/magnesium contententers through the In port. It passes through the control valve and into the main tank, where it goes from top to bottom through a bed of resin that softens it. The resin consists of specially manufactured beads that have been saturated with sodium ions. Softening occurs as the hardness minerals, the calcium and magnesium ions, in the water attach themselves to the resin and are exchanged for sodium, which goes into the water in their place. The softened water then enters the long center tube, called a riser or a "dip tube," via the strainer basket in the bottom of the tank and passes upward through the riser. The water then exits the softener via the control valve (blue arrow) and is sent to the home. When the resin becomes saturated by hardness minerals, it no longer has the ability to soften water. The water softener then automatically goes into regeneration. The regeneration process is initiated by a timer or a meter. The regeneration process is accomplished by passing very salty water from the brine tank through the resin. The brine solution is so concentrated that its high sodium content displaces the calcium and and magnesium ions on the resin. The brine tank must remain filled with softener salt at all times so that it can regenerate the softening resin again and again.

WATER SOFTENER

4. Reverse Osmosis
Reverse Osmosis Systems H2O pressure is used to force water molecules through a very fine membrane leaving the contaminants behind. Water treatment is collected from the side of the membrane, and water containing the concentrated contaminants is flushed down the drain from the "contaminated" or concentrate side. The average Reverse Osmosis system is a unit consisting of a sediment/chlorine pre filter, the reverse-osmosis membrane, a storage tank, and an activated-carbon post filter. Reverse osmosis (RO) removes most organic compounds and up to 99% of all ions present in the water, and for that reason, RO lends itself to use in places where the drinking water is salty, contains nitrates or other dissolved minerals which are difficult to remove by other methods. RO can meet most water standards with a single-pass system and the highest standards with a double-pass system. This process achieves rejections of 99.9+% of viruses, bacteria and pyrogens. Pressure in the range of 50 to 1000 psig (3.4 to 69 bars) is the driving force of the RO purification process.

REVERSE OSMOSIS SYSTEM

5. Ion Exchange Resin

Ion exchange resins consist of a polymeric matrix and a functional group with a mobile ion which can be exchanged with other ions present in the solution to be treated. The most common synthetic structures are:

Cross-linked polystyrene Cross-linked polymethacrylate Phenol-formaldehyde

Strong acid cationic resin polystyrenic type

Strong base anionic resin polyacrylic type

The polystyrene type is the most commonly used. The functional group determines whether the ion exchange resin is a cationic type or an anionic type. Although an infinite quantity of functional groups can be attached to the polymeric matrix, the most commonly used in the industry are:

Active group Sulfonic Carboxylic Ammonium

Structure R-SO3 H R-COOH R-N (CH3)3 Cl R-N (CH3)3 OH ClR-N (CH3)2 R-SH R-CH2 N(CH2 COOH)2 R-CH2 NHCH2 CH2 PO3 H

Type of resin Strong acid cation (SAC) Weak acid cation (WAC) Strong base anion (SBA) type I Strong base anion (SBA) type II Weak base anion (WBA) Chelating resins

Chelating

Ion exchange resins are most often available in a moist bead form (granular or powdered forms are sometimes used and a dry form is also available for applications in solvent media) with a particle size distribution typically ranging from 0.3 1.2 mm (16 50 mesh) with a gel or macroporous structure. Nowadays, ion exchange resins with a uniform particle size distribution are available resulting in optimum industrial operations. Ion Exchange Reactions Salt conversion: The most typical application is softening or decalcification.

2R-Na + Ca2+ -> 2R-Ca + 2 Na+ Organic acids can be also converted into their salts by passing them through a cationic resin in the appropriate form. We can also mention the Quentin process where potassium and sodium ions are exchanged against magnesium in order to minimize sugar loss in the final molasses.

6. Mixed Bed
Mixed Bed Deionisers are designed to produce high purity treated water required by the pharmaceuticals and electronic industries. These deionisers can be used as polishing units after two bed deionisers or directly to obtain high purity water. Mixed Bed Deionisers are single column units, filled with strongly acidic cation and strongly basic anion exchange resins mixed together evenly. Dissolved solids in the water are thus removed, producing water of very high quality-confirming to IP specifications of purified water. The treated water however is not free from bacteria and pyrogen. Working principle There are four distinct stages in the operation of an industrial mixed-bed deioniser: Service/exhaustion Backwashing Regeneration Rinse/remix Service/Exhaustion

Backwashing Once the resins are exhausted, the bed is backwashed. Backwashing is initiated by introducing a uniform upward flow of water through the resin bed. The backwash flow expands the resin bed releasing any entrapped particulate matter and resin fines and separates the denser cation resin from the lighter anion resin. Regeneration The first stage in the process of regeneration involves passing a dilute solution of acid, usually hydrochloric, through the cation bed. After the cation resin has been regenerated, the anion resin is regenerated by passing a dilute solution of caustic (sodium hydroxide) through the anion resin bed. As a result, the cation resin is reconverted to the hydrogen form and the anion resin to the hydroxyl form. Rinse/Remix

The final stage of regeneration is to rinse the resins of excess regenerant and then remix with air.

MIXED BED DEIONIZER DESIGN

7. Ultraviolet Treatment
Ultra-violet (UV) treatment is the disinfection process of passing water by a special light source. Immersed in the water in a protective transparent sleeve, the special light source emits UV waves that can inactivate harmful microorganisms. UV treatment works not by killing bacteria, protozoa, and viruses, but by altering their DNA so that they cannot reproduce or infect. UV treatment does not alter the water chemically as nothing is added except energy. Also, the inactivated microorganisms are not removed from the water. UV light in the 200 to 300 nanometer (nm) range is the most effective at treating bacteria and viruses. (Visible light falls in the 400-700 nm area.) For most practical UV applications in water treatment today, the light is generated by a mercury vapor lamp, or in a gas mixture that contains mercury. Mercury is the gas of choice because the light it puts out is in the germicidal wavelength range.

ULTRAVIOLET TREATMENT SYSTEM

APPLICATIONS
Producing drinking water is one of the most important applications of water treatment plant. Purified Water is used as an excipient in the production of nonparenteral preparations and in other pharmaceutical applications, such as cleaning of certain equipment and nonparenteral product-contact components. The water from water treatment plant can also be used in labs after further treatment.

HPLC Grade Water

Water used in the labs in pharmaceutical industry is highly purified water. The water from the water treatment plant contains some impurities which can interfere with the whole process while used in labs. Therefore, it is further purified using various techniques for achieving the water quality specific to a particular application.

Overview of Lab Water Grades

Norms define different laboratory water grades for both technical and economical reasons. The purpose of these norms is to ensure that the right water quality is used for a specific application, while limiting laboratory operating costs.

Types

Type 3

Type 2

Type 1

Type 3 water is the lowest laboratory water grade, recommended for glassware rinsing, heating baths and filling autoclaves, or to feed Type 1 lab water systems. Type 2 water is the grade used in general laboratory applications such as buffers, pH solutions and microbiological culture media preparation; as feed to Type 1 water systems, clinical analyzers, cell culture incubators and weatherometers; and for preparation of reagents for chemical analysis or synthesis. Type 1 water is the grade required for critical laboratory applications such as HPLC mobile phase preparation, blanks and sample dilution in GC, HPLC, AA, ICP-MS and other advanced analytical techniques; preparation of buffers and culture media for mammalian cell culture and IVF; production of reagents for molecular biology applications (DNA sequencing, PCR); and preparation of solutions for electrophoresis and blotting.

Type 1 water (Ultrapure water)

Type 1 laboratory water is the grade required for critical laboratory applications. It is also the most costly to produce, over Type 2 or Type 3.

Specifications
Parameter Resistivity TOC Bacteria Particulates > 0.2 m Pyrogens (Endotoxins) Rnases DNases Value 18,2 <5 <1 <1 < 0,001 < 0,01 <4 Unit M.cm @ 25 C ppb (g/l) cfu / ml Particulates / ml EU / ml ng / ml pg / l

Purification Systems
The purification systems used in Amol Pharmaceuticals Private Limited is Milli-Q Integral System provided by Merck Millipore PROCESS The Milli-Q Integral system uses regular tap water as feed, with pure and ultrapure water delivered by independent POD s. Following a reverse osmosis step, the Merck Millipore-patented Elix technology requires no resin replacement or upstream softening process to produce consistent, superior quality purified water. Merck Millipore Elix modules consist of an anode and a cathode separated by alternating anion-permeable and cationpermeable membranes. The compartments used for ion removal are filled with high quality ion-exchange resin that is permanently and gently regenerated by a weak electric current, eliminating the need for chemical regeneration or replacement of DI resin cartridges Activated carbon beads fill the cathode compartment to ensure dispersion of the hydroxyl ions generated over a large volume, preventing the high pH that would lead to CaCO3 precipitation.

Need and Importance of Ultrapure Water

Organic material in the water can contribute to bacterial proliferation as a foodstuff, react in unwanted ways with biochemical reactions in bioprocessing and, in severe cases, leave unwanted residues on production parts. Metallic and anionic contamination in ultra pure water systems can shut down enzymatic processes in bioprocesing or interfere in the chemical reactions.

DISPOSAL METHODS
1. LANDFILL Disposing of waste in a landfill involves burying waste to dispose it off, and this remains a common practice in most countries. Landfills were often established in abandoned or unused quarries, mining voids or borrow pits. A properly-designed and well-managed landfill can be a hygienic and relatively inexpensive method of disposing of waste materials. Older, poorly-designed or poorly-managed landfills can create a number of adverse environmental impacts such as wind-blown litter, attraction of vermin, and generation of liquid leachate. Another common byproduct of landfills is gas (mostly composed of methane and carbon dioxide), which is produced as organic waste breaks down anaerobically. This gas can create odor problems, kill surface vegetation, and is a greenhouse gas. In a modern landfill, refuse is spread in thin layers, each of which is compacted by a bulldozer before the next is spread. When about 3 m (about 10 ft) of refuse has been laid down, it is covered by a thin layer of clean earth, which also is compacted. Pollution of surface and groundwater is minimized by lining and contouring the fill, compacting and planting the cover, selecting proper soil, diverting upland drainage, and placing wastes in sites not subject to flooding or high groundwater levels. Gases are generated in landfills through anaerobic decomposition of organic solid waste. If a significant amount of methane is present, it may be explosive; proper venting eliminates this problem. 2. INCINERATION Incineration is a disposal method that involves combustion of waste material. Incineration and other high temperature waste treatment systems are sometimes described as "thermal treatment". Incinerators convert waste materials into heat, gas, steam, and ash. Incineration is carried out both on a small scale by individuals and on a large scale by industry. It is used to dispose of solid, liquid and gaseous waste. It is recognized as a practical method of disposing of certain hazardous waste materials (such as biological medical waste). Incineration is a controversial method of waste disposal, due to issues such as emission of gaseous pollutants. Incineration is common in countries such as Japan where land is scarcer, as these facilities generally do not require as much area as landfills. Waste-to-energy (WtE) or energy-from-waste (EfW) are broad terms for facilities that burn waste in a furnace or boiler to generate heat, steam and/or electricity. Combustion in an incinerator is not always perfect and there have been concerns about micropollutants in gaseous emissions from incinerator stacks. Particular concern has focused on some very persistent organics such as dioxins which may be created within the incinerator and which may have serious environmental consequences in the area immediately around the incinerator. On the other hand this method produces heat that can be used as energy. 3. RECYCLING METHODS The process of extracting resources or value from waste is generally referred to as recycling, meaning to recover or reuse the material. There are a number of different methods by which waste material is recycled: the raw materials may be extracted and reprocessed, or the calorific content of the waste may be converted to electricity. New methods of recycling are being developed continuously, and are described briefly below.

PHYSICAL REPROCESSING

The popular meaning of recycling in most developed countries refers to the widespread collection and reuse of everyday waste materials such as empty beverage containers. These are collected and sorted into common types so that the raw materials from which the items are made can be reprocessed into new products. Material for recycling may be collected separately from general waste using dedicated bins and collection vehicles, or sorted directly from mixed waste streams. The most common consumer products recycled include aluminum beverage cans, steel food and aerosol cans, HDPE and PET bottles, glass bottles and jars, paperboard cartons, newspapers, magazines, and cardboard. Other types of plastic (PVC, LDPE, PP, and PS) are also recyclable, although these are not as commonly collected. These items are usually composed of a single type of material, making them relatively easy to recycle into new products. BIOLOGICAL REPROCESSING

Waste materials that are organic in nature, such as plant material, food scraps, and paper products, can be recycled using biological composting and digestion processes to decompose the organic matter. The resulting organic material is then recycled as mulch or compost for agricultural or landscaping purposes. In addition, waste gas from the process (such as methane) can be captured and used for generating electricity. The intention of biological processing in waste management is to control and accelerate the natural process of decomposition of organic matter. There are large variety of composting and digestion methods and technologies varying in complexity from simple home compost heaps, to industrial-scale enclosed-vessel digestion of mixed domestic waste. Methods of biological decomposition are differentiated as being aerobic or anaerobic methods.

Common Waste Disposal Facilities in Rajasthan

Waste
ETP sludge Residue and Waste Biowaste

Category
34.3 28.8

Disposal Facility
Rajasthan Waste Management Project Continental Petroleum Limited Instromidix

APPENDIX
Dissolved Oxygen (DO)
The measurement of dissolved Oxygen indicates immediately the purity of water and is important for maintaining aerobic conditions in the receiving waters and in the aerobic treatment of sewage and industrial waste waters. Further DO test is the basis for BOD Test which is used to evaluate the pollution strength of waste waters and rate of biochemical oxidation.

Biochemical Oxygen Demand (BOD)

BOD is the quantity of oxygen required by bacteria and other micro organisms,during the biochemical degradation and transformation of organic matter(present in waste water)under aerobic conditions.The BOD determination involves the measurement of dissolved oxyzen content of the sample,before and after 5 days incubation at 20C.

Chemical Oxygen Demand (COD)

This test is highly useful to find out the pollutional strength of industrial effluents and sewage. Chemical Oxygen Demand is the oxyzen requirement of a sample for oxidation of organic and inorganic matter. In COD test, the sample is subjected to a chemical oxidation induced by chemical reagants and it is an artificial oxidation by which both biologically oxidizable and biologically inert matter is oxidized. Hence, the COD value is always higher than BOD value.

Suspended Solids
The undissolved matter present in a water or waste water is usually reffered as suspended solids. It is one of the important parameters in judging the pollution potential of an effluent, pollution load on receiving streams and also to decide efficiency of treatment units.It is particularly useful in determining the load on secondary biological treatment units, after the removal of settable solids in primary settling tanks.

Mixed Liquor Suspended Solids (MLSS)

MLSS is a test for the total suspended solids in a sample of mixed liquor. The concentration of suspended solids found in the mixed liquor is typically much greater than that found in the raw or treated water. MLSS concentrations are often greater than 1,000 mg/L, but should not exceed 4,000 mg/L.

MLVSS, or Mixed Liquor Volatile Suspended Solids

MLVSS is a test for the amount of volatile suspended solids found in a sample of mixed liquor. Volatile solids are those solids which are burnt up when a sample is heated to 550C. Most of the volatile solids in a sample of mixed liquor will consist of microorganisms and organic matter. As a result, the volatile solids concentration of mixed liquor is approximately equal to the amount of microorganisms in the water and can be used to determine whether there are enough microorganisms present to digest the sludge.

Total Organic Carbon (TOC)

Total Organic Carbon (TOC) is an indirect measure of organic molecules present in pharmaceutical carbons measured as carbon. TOC can also be used as a process control attribute to monitor the performance of unit operations comprising the purification and distribution systems.