Common Effluent Treatment Plant

COMMON EFFLUENT TREATMENT PLANT

CETP

DATE: 04-01-2010 PLACE: MIDC, KURKUMBH

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PROFILE OF THE COMPANY

Name of the company: Common Effluent Treatment plant. Plant Location: MIDC, Kurkumbh. Office Address: Common Effluent Treatment plant, D-17,MIDC, Kurkumbh Industrial Area, Taluka- Daund, Dist. Pune-413 803S. Website: N.A Products: Common Effluent Treatment plant Annual Turnover: N.A Capacity Industry: 1000 m3. Establishment year: 1996-97 Investment: Rs (18.5 + 1.5) crores for Effluent Treatment Plant Number of Employees: 39 Concern person:-

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Introduction:
The kurkumbh industrial estate is about 70 kilometers east of Pune and the estates total area is about 483 hectares. The Kurkumbh industrial estate has about 60% small scale industries, 20% medium scale and 20% large scale industries. The products manufactured at Kurkumbh industrial estate are varied and consist of copper wire, ice, liquid ammonia, air and chemical vessels, foam arrestors and emulsifiers, tanks, vessels, chemical equipment, mosaic tiles, engineering and fabrication, silicate and methyl silicate acids, benzene and chlorobenzene, polyethylene bags, paint and varnish, chemicals, pharmaceuticals, orthonitrobenzene, dye intermediates, sulphuric acid, plastic bottles, edible oils and poha and chana dal. The kurkumbh environmental protection co-operative society maryadit have an existing CETP which has been setup to cater for the wastewater discharged from the small scale industrial (SSI) units and large scale industrial (LSI) units. The SSI units provide preliminary treatment (oil and grease removal and PH adjustment) at their unit level and discharge the wastewater into the conveyance system leading to the CETP. The bulk of industrial pollution in India is caused by the small and medium scale industrial (SMIs) sector. A small scale unit is defined as any industry whose plant and machinery are valued more than 25 lakhs rupees but does not exceed 5 crore . SMIs account for over 40% of the total industrial output in the country and generate over 44% of hazardous wastes alone as compared to 13% generated by the large scale industry. Many of the Small Scale Industries are unable to put up the treatment systems individually, CETP's (Common Effluent Treatment Plants) is envisaged to benefit such industries in treating its effluent before disposal whether it is in stream, land, sewage system or in rivers and seas. CETPs are set up in the industrial estates where there are clusters of small scale industrial units (Siss) and where many polluting industries are located. The proposal for setting up of CETPs by such industries is to be submitted by the CETP Association to the respective State Pollution Control Board, which after examining the proposal and obtaining commitment from the concerned State Government regarding its contribution will give their recommendation to the
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Ministry of Environment and Forests for consideration , the Ministry examines the proposal and takes the decision through a Screening Committee constituted in this regard for providing support from the Central Government.

History:
After the formation of Maharashtra State on May 1, 1960, the Government of Maharashtra constituted a "Board of Industrial Development" (BID) on October 1, 1960, under the Chairmanship of Shri. S. G. Barve, I.C.S. The various committees recommendations received in the industries department were taken up for implementation and as per the Borkar Committee's recommendations; development of Ulhas Valley Water Supply was entrusted to the Board of Industrial Development (BID). The BID framed the legislation and it was introduced before the state legislation and passed in the form of"Maharashtra Industrial Act" which gave birth to MIDC, as a separate corporation on August 1, 1962. The key historical policy decisions taken by CETP certainly changed the socioeconomic scenario of the state as its activities spread in the interior. The important policy decision of setting up "independent filtered, potable water supply system of adequate capacity" as essential infrastructure for industrial development was the most intelligent step taken by CETP right in the beginning. It stabilised the population base near the industrial areas. The strategic wise decision taken simultaneously to provide water supply to nearby domestic population from the capabilities created by CETP of their own water supply system resulted in phenomenal urban growth in the nearby small towns and villages. In the first phase to treat the effluent collected from the industries to the disposable norms stipulated in the Environment Protection Act, 1986 and in the second phase it will be treated to the recycling standards. MIDC has entered into the Memorandum of Understanding (MoU) with the Industries Association from Tarapur, Badlapur, Ambernath, Dombivli, ThaneBelapur, Patalganga, Roha, Mahad, LoteParshuram ,Kalyan-Bhivandi, Solapur,
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Sangli, &Butibori.

Reason for upgradation in 2006 Dissolve O2 was not sufficient in Floating Aeration as its depth was 2.5m which was increased up to 4.7m for Floating Aeration in 2006 which costs up to Rs1.5 cr.

Objectives:
Common Effluent Treatment Plant (CETP) is established in order to make a cooperative movement of pollution control especially to treat the effluent, emanating from the clusters of compatible Small-Scale Industries (Siss). Objective of the CETP is therefore, to reduce the treatment cost to be borne by an individual member unit to a maximum while protecting the water environment to a maximum. It promotes industrial growth.

Contribution for construction of the CETP:

State Subsidy: Central Subsidy: Entrepreneurs contribution: Loan from financial institutes:

25% of the total project cost 25% of the total project cost 20% of the total project cost 30% of the total project cost

ABOUT COMMON EFFLUENT TREATMENT PLANT

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MIDC kurkumbh was started around the year 1996-97 with a total investment of 18.5 Cr. For Effluent treatment plant + 1.5 Cr. In 2006. There are some 76 Industries situated in MIDC kurkumbh of which 12 are Large Scale with investment of more than 10 Cr. and 61 Small Scale industries with less than 10Cr. investments, leaving about 3 Medium Scale industries. MIDC is a government company which serves for no profit no loss. MIDC kurkumbh is the first chemical zone in Pune and the Mumbais Copper Capper is the very first MIDC Project. Common Effluent Treatment Plant (CETP) is the concept of treating effluents by means of a collective effort mainly for a cluster of small scale industrial units. A rapid industrialization has lead to the industrial effluents & sewage resulting in water pollution. The effluents contain hazardous chemicals & heavy metal ions like chromium, nickel, copper, lead, arsenic etc. These are toxic in nature & harmful to environment hence must be treated to effluent. Each large scale Industry must have its own Effluent treatment plant. The measurements of safety that the Large Scale Industry should follow are as follows: ph value 6 - 8

C.O.D - 250 mg/lit B.O.D - < 100 mg/lit T.S.S - <100 mg/lit T.D.S 2100 mg/lit Oil & Grease 10% Each Small Scale Industry produces around 200 m3 of Effluent per day. For Small Scale Industries the measurements are as follows: ph value 5.5 to 8.5 C.O.D - 1000 mg/lit B.O.D - 3000 mg/lit
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T.S.S - 1000 mg/lit T.D.S 8000 mg/lit Oil & Grease 10% Government policies have been biased toward small industries as employment generators, even though small industries are highly polluting. The SSI policy has no thought on the environmental planning. Promotion of small enterprise is widely seen as a desirable way to achieve sustainable development; for that result, however, their pollution problems, among others, must be overcome. To deal with the effluent in these SSIs the concept of Common Effluent Treatment Plan (CETP) was introduced with a hope that not only it would help the industries in pollution.

Process of Treatment:
The scheme of treatment is depicted in figure as given below. The treatment comprises of many stages: 1. Collection

The effluents from the industrial units is collected and led via conveyance system to the common effluent treatment plant site. The flow from SSI units is led directly to the screen chamber.
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2.

Course Screening: Raw effluent is initially passed through screen to trap all the floating material like wooden plank, plastic bags, paper etc. Initially its passed through coarse screen and later on through fine screens. All the material trapped in the screen are removed manually with the help of racks .The screened material are disposed offsuitably. 3. Oil & Grease removal:

Many of industrial units discharge oil in waste water due to leakage of oil from the system .Grease also comes in water from lubricating system. The oil & Grease are required to be removed in oil\Grease removing chamber effluent enters and due n abatement but also as a step towards the clean environment to availability of more cross sectional area, velocity of effluent suddenly drops down. Since the specific gravity of oil & Grease is lower than water, it floats on the top surface. From top surface oil & Grease are removed by manual skimmer.
4.

Grit Removal: The wastewater is then taken to grit chamber for removal of grit. Two units are provided and are to be
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used in a cyclic manner. Cleaning of grit chamber is to be done manually.

5.

Equalization chamber: The flow of effluent varies from time to time .At the same time quality of effluent changes during different periods of the day. Since the treatment plant is designed for a particular flow rate and quality, it is essential to have an equalization tank prior to main treatment units. In this equalization tank a detention period for effluent is given to take care of surge load and also the Flow during lean period. The effluent in the equalization tank is pumped at constant flow rate to treatment plant.

6. Pre Chlorination: Effluent contains lot of organic matter, which gets oxidized later on by the reaction with dissolved oxygen in water. Normally oxygen is not available in effluent and hence it ultimately consumes oxygen from the river water or in any other natural source of water. The purpose of Pre
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Chlorination is to oxidize these organic and inorganic materials by chlorine. 7. Clarification: Any suspended solids generated due to Pre chlorination are also removed in clarifier. The clarifier is provided with tube packing to enhance the settling of suspended solids. Since clarifier is designed with tube packing it has been designated as Tube settler. After pre chlorination, effluent goes to tube settler via flash mixer. In flash mixer. Alum solution is dosed as coagulant. This coagulant aids in flocculation. The flocculated water flows upwards through tube settler. The suspended solids settle due to higher specific gravity of floes. Due to presence of PVC tubes, the settling height of particles reduces substantially resulting in higher surface overflow rates. Alum solution is used as coagulant.

Water Treatment Units:

They are manufactures of pressure sand filters, activated carbon filters, dual media filters and UV filters as per the specific clients requirements. They offer a wide range of auto operated filters which can operate based on time schedule or total water passed through it. Their plants are available in different capacities. The auto operated plants can work on OBR principle or conductivity of treated water. If the plants are cascade type the same can be controlled through microprocessor / PLC based controller.

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Reverse Osmosis (RO) Filtration Plants:

They have also supplied and commissioned complete mineral water plants based on RO, UV and Ozonation. They also provide RO components like Membranes, pressure housing, pressure pumps, online calibrated meters etc. and also take repairing jobs of the RO plants.

Chemicals Used in the treatment of Waste Water: Alum Bleaching Powder Poly Electrolite

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The CETP consists of the following units:

Equalization Tank Flash Mixer Flocculator Dissolved Air Floatation Unit Aeration Tank Secondary Clarifiers Each member unit is required to arrange for pre-treatment of the effluent to meet the CETP inlet norms. The pre-treated effluent from the member is pumped to the Equalization Tank where it is thoroughly mixed/equalized with the help of coarse bubble diffused aeration supplemented by a Turbo Aerator. From the Equalization tank the effluent flows into Flash Mixer where coagulants & flocculants are added. From Flash tank effluent flows into Flocculator where coagulation & flocculation of suspended solids, colloids & some of the dissolved pollutants take place.

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The overflow from the Flocculator goes to Dissolved Air Floatation (DAF) unit where, pressurized recycled effluent is mixed with compressed air to achieve super saturation. The saturated recycle flow is released at about atmospheric pressure at DAF tank which results in the formation of fine bubbles. These fine bubbles get attached with flocculated particles & are floated to the top of the tank. These particles as well as those settled at the bottom of the tank are removed & collected by the top and bottom scrappers in the form of primary sludge is collected in the Primary Sludge Holding Tank from where it is sent to Centrifuge Decanter for dewatering. The dewatered sludge is then disposed off into Secured Landfill Site. From Flocculator, the effluent flows to Aeration Tank by gravity. The organic matter is aerobically degraded by the micro-organisms contained in the activated sludge. Nutrients in the form of nitrogen & phosphorous containing compounds are added as per the requirement & various parameters as well as concentration of nutrients are closely monitored & maintained to achieve the maximum degradation of organics. The effluent from aeration tank flows into the Secondary Clarifiers after passing through the Flow Distribution Chamber. Provision is made for adding coagulant in the clarifiers depending on the requirement. The suspended solids get settled by gravity & are collected at the bottom of the clarifiers from where they are taken to the Sludge Sump. The Sludge is taken into Sludge Holding Tank from where it is pumped to Centrifuge Decanter for dewatering. The dewatered sludge is transported to Secured Land Fill Site for final disposal.

Machineries used for treatment:

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Total Capacity:

The Total Capacity of the Industry is 1000 m3. In CETP 1000 m3 of water if filtered out of which 400 m3 of purified water is used by MIDC and the remaining 600 m3 are supplied for the forest i.e. Roti Forest which is situated 7 kms from MIDC. MIDC charge Rs. 5/m3 for Large Scale Industries and Rs. 12 /m3 for Small Scale Industries.

Advantages
Saving in capital and operating cost of treatment plant. Common treatment is always cheaper than small scattered treatment units. Availability of land which is difficult to be ensured by all the treatment units in the event they go for individual treatment plant. Contribution of nutrient and diluting potential, making the complex industrial waste more amenable to degradation. The neutralization and equalization of heterogeneous wastes makes its treatment techno-economically viable. Professional and trained staff can be made available for operation of CETP which is not possible in case of individual plants. Disposal of treated waste water & sludge becomes more organized. Reduced burden of various regulatory authorities in ensuring pollution control requirement.

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CONCLUSION
Date of visit: 04-01-2010 Teacher Guide: Mrs. Prachi Kulkarni Company Guide: Mr. Yama The visit was organized by the college authorities as a part of partial fulfilment of BBm(IB) semester IV. The students were asked to visit in group of 35. The company authorities took keen interest in the visit. They made sure that the students were left with no questions unanswered or no process unexplained. After the formal visit was completed the authorities arranged a meeting with the students to furnish them with complete information about the industry. The Total Capacity of the Industry is 1000 m3. In CETP 1000 m3 of water if filtered out of which 400 m3 of purified water is used by MIDC and the remaining 600 m3 are supplied for the forest i.e. Roti Forest which is situated 7 kms from MIDC. MIDC charge Rs. 5/m3 for Large Scale Industries and Rs. 12 /m3 for Small Scale Industries. It was updated in 2006.

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