Chennai Metropolitan Water Supply and Sewerage Board

Advanced Water Treatment Technologies Chennai Initiatives Workshop conducted by MoUD, New Delhi

11.03.2011

WATER TREATMENT TECHNOLOGIES ADOPTED

Conventional Water Treatment

270 MLD WTP at Kilpauk (1914 Slow sand Filters 60 MLD) / (1959 Rapid sand filters 45 MLD) / (1973 Rapid sand filters 135 MLD) / (1990 Rapid sand filters 90 MLD)

300 MLD WTP at Puzhal (1996)

180 MLD WTP at Vadakuthu (2004) Pulsator Technology based Water Treatment

530 MLD WTP at Chembarambakkam (2007)

Brackish water (R.O. based) Water Treatment Sea water Desalination

100 MLD Plant at Kattupalli, Minjur (2010)

100 MLD Plant at Nemmeli Ongoing and completed by 2012 Sewage Renovation (TT / RO based) for Industrial use Collaboration with Industries (CPCL / MFL / GMR Vasavi) 41 MLD

NEED TO GO IN FOR LATEST WATER TREATMENT TECHNOLOGIES

Slow sand filters

occupies more space limitations in expansion Low filtration rates limitations in meeting the demands Replacement of media due to clogging / Time consuming Danger of flooding during Monsoon due to open to air construction

WATER TREATMENT PLANT AT RED HILLS ( BOT) - 1996

Capacity Work completed & Commissioned Cost

300 MLD 1996 Rs.50.43 Crore

The Operation & Maintenance of the Plant is done by Private Contractor except the major repairs and replacement which are being carried out by the Board

300 MLD WATER TREATMENT PLANT AT PUZHAL - PROCESS FLOW CHART

300 MLD Water Treatment Plant at Puzhal

Year of Construction Capacity

- 1996 - 300 MLD

Operation & Maintenance - M/s VA Tech Wabag Ltd

Period of contract - 3 Years

Date of commencement
Contract Value

- 16.12.2007
- Rs 7,37,55,068/- for 3 years.

NEW VEERANAM PROJECT INFRASTRUCTRES -2004

Raw water pumping, Treatment Plant, Treated water pumping, 228 km pipeline and WDS Capacity - 180 MLD Work completed & commissioned - 2004 Project Cost - Rs. 720 Cr.
After the completion of the construction and commissioning the same contractor are entrusted with O&M including all major repairs and replacements for 5 years

180 MLD WATER TREATMENT PLANT AT VADAKUTHU - PROCESS FLOW CHART

180 MLD Water Treatment Plant at Vadakuthhu

Year of Construction Capacity

- 2004 - 180 MLD

- M/s. VA Tech Wabag Ltd 2 Packages - M/s. IVRCL Ltd 2 Packages

Operation & Maintenance - M/s. TMP Manoharan & Co

Period of contract

- 5 Years

Date of commencement
Contract Value

- 08.09.2010
- Rs 23.11 Crore for 5 years.

530 MLD CHEMBARAMBAKKAM WATER TREATMENT PLANT

TREATMENT PROCESS

O&M Cost = Rs.45 Crore for 7 yrs

Total Cost Rs.134.9 Crore (French Assistance = Rs.33.5 Crore + CMWSSB Rs.107.0 Crore

Vacuum blower

Air inlet Valve closed

High level

THE PULSATOR TECHNOLOGY

water surface

Low level

clarification area

Top surface sludge blanket

Raw water Raw water + + Raw Aluminium Aluminium water + sulphate sulphate Alum sulphate Sludge blanket with downward motion Sludge concentrator

sludge draw down pipe to sludge channel

Small raw water flow rate at lateral distribution pipe

baffle plates

ADVANTAGES OF PULSATOR TECHNOLOGY

Low chemical consumption

Low water losses on sludge extraction

Low power consumption Low maintenance Low operator input Excellent treated water quality - SS (Low load on filters) - Colloids - Algae

ADVANTAGES OF AQUAZUR FILTERS

High Rate Gravity Sand Filters
More filtering capacity
INLET CHANNEL

False Floor Fitted with Nozzles

Effective floor usage

Uniform Sand media for filtration

In-depth clogging longer filtration cycle

Constant Head & Constant Rate Filtration

Better filter operation

FILTRATION MODE

Washing - Simultaneous Air & Water Scour

Effective cleaning of bed with less water

Washing - Simultaneous Air & Water Scour

SCOUR AIR

BACKWASH MODE

B/W OUTLET

B/W WATER

BRACKISH WATER R.O. DESALINATION PLANT

 Metro water has taken a considered decision to focus on Fishermen's Colonies and economically disadvantaged section to supply them with good quality water for drinking and cooking purposes. Since most of them are located close to the sea and in the tail end of the city water supply distribution system, they suffer from lack of potable water, resulting in major health related problems.
A conscious decision was taken to locate a battery of Reverse Osmosis Plants to help these groups by supplying the potable water by treating locally available brackish ground water through Reverse Osmosis Process. There are three Reverse Osmosis Plants located one at Velachery (4.5 lakhs litres capacity) and the others at Nochikuppam (1.5 lakh litres capacity) and Kasimedu (1.5 lakh litres capacity). During the year 2001 drought, two new Reverse Osmosis Plants were installed one at Ayothiakuppam (1.00 lakh litre capacity) and another at Kasimedukuppam (Royapuram) serving a population of about 5000 at each location.

 The Reverse Osmosis Plants consists of open wells and Bore wells to draw the required brackish water for treatment through the Reverse Osmosis Plant. The raw water drawn from the wells is stored in the storage tanks and pumped to the Dual Media filters consisting of quartz sand and anthracite wherein suspended particles is removed.

The filtered water from the Dual Media filter is pumped to a micron filter to remove the micron size particles and then fed into the Reverse Osmosis Process Unit by means of high pressure pumps.

 The Reverse Osmosis process module consists of a thin film composite of polyamide membrane. When brackish water is pumped with high pressure through this membrane, the dissolved solids are removed and the output water is of potable quality with dissolved solids content below 500 ppm. The rejects from the Reverse Osmosis modules with high salt content is put into the nearby sewer system for disposal since the quality is within the permissible limit to dispose through the domestic sewer.

INSIDE VIEW OF R.O.PLANT

VIEW OF R.O.PLANT

SEA WATER DESALINATION

Need for Alternate Non-Rain dependent Sources (Sea water Desalination Project)
Even after implementation of the various water supply augmentation projects and water conservation measures, there is still a shortfall in meeting the water demand of Chennai City and adjoining areas.

Further all the existing sources are depend on monsoon and subject to change in weather patterns and not 100% reliable and assured supply.
Hence, it is necessary to examine the possibility of identifying another reliable and assured source of water supply to bridge the gap between demand and availability.

Chennai - Sea water Desalination Project - Contd.,

Govt.of Tamil Nadu is determined to implement a combination of schemes to make available

Sufficient quantity of water during normal years
Minimum lifeline supply during Critical drought years

Govt.of Tamil Nadu has therefore decided to implement two Desalination Plants of 100 MLD capacity each

This will ensure lifeline water supply to the residents of Chennai during drought years

TECHNICAL ASPECTS OF THE PROJECT

Project Terms Operations Period Desalination Process Conversion rate of drinking water from sea water No.of RO trains No.of Pressure Vessels Setting up of 100 MLD Seawater Plant on DBOOT basis at Kattupalli, Minjur Bulk Water Purchase Agreement dated 13.09.2005 25 Years Reverse Osmosis (RO) 45% 5 248 in each RO train

Number of Membranes
Type of Membrane

7 in each pressure vessels

Composite polyamide spiral wound membranes

TECHNICAL ASPECTS OF THE PROJECT

Pre-treatment

Coagulation & Flocculation; Clarifier; 2-stage media Filtration Pressure Filtration & Cartridge Filtration Energy Recovery System using the principle of positive displacement and isobaric chambers As per IS 10500 : 1991

Energy Recovery System

Product Water Quality

SEAWATER INTAKE TRAVELLING SCREEN & FLUSHING PUMPS

The raw sea water is drawn by gravity from an intake tower erected at 635 m away from the shoreline.
High Density Poly Ethlene (HDPE) pipeline of 1600 mm dia is laid on the seabed for the drawal of 237 MLD raw seawater. Bar screens and dual flow travelling band screens installed in the seawater sump protect the pumps . Seawater from the sump is pumped to Pre-treatment Units

Chemical Dosing unit for Pre-Treatment

1. 2. 3.

Sulphuric Acid is added to decrease pH of sea water in order to maxmize the coagulation Ferric Chroride is added to enhance coagulation of seawater required in the plant. Sodium Hypo chlorite solution is added to disinfect seawater.

Pre-treatment Flocculation Chamber

The seawater from seawater pump house is pumped to the first pretreatment system namely, flocculation chamber. Here the suspended, dissolved and colloidal are removed by means of adding chemicals thereby increasing the efficiency of decantation. Volume to be treated 237 MLD Average volume per hour 9,921 cum/hr.

Pre-treatment - Gravity Settlers

The flocculated water is uniformly distributed in the Gravity Settlers. The Gravity Settlers have been designed with 4 lamellar decanters with pulsating mire beds with a capacity to treat 237 MLD. The GRP lamella plates are installed with 60 degrees of inclination, each vase contains 52 lamella plates

Intermediate Pumping Station

The filtered water from the Dual Media Filters is pumped from the intermediate sump cum pump house for the next stage of pressure filtration to obtain clear seawater. Discharge 945 cm/hr

Pressure Filter Vessels

The water pumped from the intermediate sump cum pump house is passed through pressure filters to improve the clarity of the seawater No.of Pressure Filters - 16

Cartridge Filters

This is the last stage of pre-treatment by which the ultra fine particles, present in the filtered seawater are removed. There are 10 No.of Cartridge Filters.

Reverse Osmosis Process Unit with pressure vessels

Reverse Osmosis is diffusive mechanism wherein the feed water is highly pressurized using High Pressure pumps before passing through a sequence of membranes placed in a Pressure Vessel, to obtain permeate water or desalinated water.

The water is pressurized to 58 Bar pressure.

The plant has a set of 5 Reverse Osmosis modules each producing 20 MLD of desalinated water.

Energy Recovery System

The pressure in the reject brine water system is nearly 56 Bar.

The pressure energy in the reject brine water is recovered at the outlet of the membrane by means of pressure exchangers. The high pressure brine exchanges pressure with the pre-treated feed water in the energy recovery system and equally pressurized with Booster Pumps before combining with the feed water from high pressure pumps for the desalination process. The energy (Power) requirement is reduced by nearly 82%

Post Treatment Units

The desalinate water flowing out of the Reverse Osmosis process unit is rematerialized and pH correction is carried out by adding chemicals such as lime, Carbon-di-oxide and Sodium hypo chlorite solution

Product Water Tank

After the post treatment the product water is collected in a 20 Million litres capacity Underground Tank. Under ground Tank water is supplied by the company to the CMWSS Board for transmission and distribution to Chennai City

100 MLD DESALINATION PLANT - NEMMELI Mass flow diagram

Location of the plant at Nemmeli

100 MLD DESALINATION PLANT AT NEMMELI

Sl. No Name of work Name of the contractor M/s V.A.Tech Wabag Limited in consortium with M/s IDE Technologies, Israel. M/s Mecon Limited in Consortium with M/s ADECO Technologies Ltd/SOECO M/s Larsen & Toubro Limited Construction Cost (Rs. in Crore) O & M cost for 7 years (Rs. in Crore) Contract Period

Construction of 100 mld capacity Desalination Plant PMC for Plant

533.38

500.29

24 Months

13.46

24 Months

Conveyance System

121.47

1.02

20 Months

REASONS OF ADOPTING ULTRA FILTRATION FOR TSS REMOVAL IN NEMMELI DESALINATION PLANT

Occupies less land area (From 40 Acres at Kattupalli and 19 Acres at Nemmeli Enhances R.O.Membrane life from 3 to 5 years at Kattupalli and 5 to 7 years at Nemmeli Ultra filtration is used for most of the plants commissioned for the last 5 Years

SEWAGE RENOVATION FOR INDUSTRIAL USE

SEWAGE TREATMENT PLANT ACTIVATED SLUDGE PROCESS FLOW DIAGRAM

1. PRIMARY AND SECONDARY TREATMENT

BOD5 = 350 mg/l TSS = 400 mg/l Feacal coliform = 4.6 x 106 MPN/100 ML

Screening Screen chamber

Grit Grit chamber

Parshall flume

A
Primary clarifier

Return Sludge Aeration Tank

Inlet chamber

Raw Sludge Balancing tank Chlorine contact tank Treated Sewage Discharge in Coovam river
BOD5 = <20 mg/l TSS = <30 mg/l Faecal coliform = <10000 MPN/100 ML

Secondary clarifier

LEGEND

Primary Treatment
Biological treatment chlorination

Excess Return Sludge C

SLUDGE TREATMENT AND POWER GENERATION

Raw Sludge

B
Excess Return Sludge

2. SLUDGE TREATMENT
C

Supernatant SLUDGE THICKENER

Supernatant

Centrate

Return to Primary clarifier

DIGESTER

CENTRIFUGE

Sludge for Disposal

Bio-Gas
GAS HOLDER SCRUBBER UNIT

Methane For Power Generation

GAS ENGINE Power For plant

48

LEGEND Sludge treatment Power generation

Excess Bio- Gas

Gas Burner

TERTIARY TREATMENT PLANTS INSTALLED BY CPCL AT MANALI

SEWAGE RECLAMATION PLANT-1

(capacity: 475 Cu.M/Hr)

Installed with old lime process by M/s. Hindustan Dorr Oliver in 1991-92 and debottlenecking with UF system was done by Ms. Doshi Ion Exchange Limited in 2004-05. Consists four RO banks with each 110Cu.M/Hr feed (3 banks operation and one standby)

Sewage Reclamation Plant - I (SRP-I)

Secondary treated sewage
3.0MGR

Chlorine Surface Aeration Tanks

Clarifiers

FeCl3 & Anionic Poly dosing Hydrotreater

Intermediate storage pond

Refinery / Canteen Sewage

UltraFiltration
Chemical dosing SBS,HCl,Antiscalant UF Product tank Cartridge filter

Multimedia filter

Pressure sand filter

1.5 MGR for CT makeup

Reverse Osmosis

Permeate

Degasser

Old permeate tank (PT-1)

Reject

Cooling Tower make-up or Additional RO feed ZDPII

Rejects to RORR

DM Plant

SEWAGE RECLAMATION PLANT-2

(capacity: 475 Cu.M/Hr)

Installed with state of the art technology of Sequential Batch Reactor (SBR) by M/s. VA Tech WABAG in the year 2006-07. Consists four RO banks with each 110Cu.M/Hr feed (all four continuous operation) & Reverse Osmosis Reject Recovery (RORR) two banks each with 40 Cu.M/Hr feed

Sewage Reclamation Plant - II (SRP-II)

Secondary treated sewage
2.5MGR

FeCl3 & Anionic Poly dosing Sequencing Batch Reactor Flash Mixer High Rate Clarifier
Pressure sand & Multi grade filter

Chemical dosing SBS,HCl,Antiscallant

Degasser

Reverse Osmosis

Cartridge filter
Reject

UltraFiltration

Break point chlorination

Permeate

New permeate tank (PT-2)

Reverse Osmosis Reject Recovery

Final Reject to MPL-II

DM Plant

SEQUENCE OF SEWAGE TREATMENT PLANT

Sewage receipt (Equalisation) Boilogical treatment (BOD /COD & Ammonia reduction) Chemical treatment (Coagulation & Flocculation) Filtration (SS & NTU reduction)

Ultra filtration (removal of colloidal of size 0.01microns)

Chemicals

Cartridge Filtration ( Removal of chemical and other dusts of size upto 10 microns) Reverse Osmosis (Removal of dissolved particles of size 0.0001microns) Storage / Export to Refinery

BIOLOGICAL TREATMENT

Aerator : Continuous growth of MLSS (Living micro organism) and diffusion of oxygen. The micro organism consumes organic and inorganic load in feed water. (Results in BOD & COD reduction and also ammonia reduction through nitrification). Clarifier: The sludge ( MLSS ) is settled. Ammonia removed through denitrification. (Note : Sequential batch reactor combines both the operation in a single unit in SRP-2)

CHEMICAL TREATMENT

Hydro Treater High rate clarifier : coagulation of suspended particles and phosphates by addtion of ferric chloride and flocculation by addition of anionic poly electrolyte Chlorination Break point chloriantion: Disinfection of bacteria and removal of residual ammonia by conversion to chloroamines

FILTRATION Pressure Sand / Multimedia Multi grade filters : Removal of particle size upto 0.45 microns and iron thereby reducing Suspended Solids (SS) & Trubidity (NTU). Pressure sand filters loaded with grades of pebbles , coarse and fine sand Multimedia filters have additional layer of Anthracite for polishing CARTRIDGE FILTRATION Removal of chemical dust due to addition of Hydrochloric acid, Sodium Bi sulphite and Antiscalants and dust from feed tanks (up to particle size 10 microns) The cartridge filter is of spiral wound and thread type and the thread made of Poly propylene or polyethylene material.

ULTRA FILTRATION
Removal of colloidal particles up to 0.01 nm size thereby reducing the Silt Density Index (SDI) of RO feed water.

The Ultra filtration membranes are made up of Polysulfones material

In SRP-1 alone the UF is of Cross flow filtration type (with reject) and in all other units of Dead end filtration (without reject)

COST FOR DIFFERENT SOURCE WATER

Sl. No 1 2 3 4 5 6 7 8 Source of water Surface Water (KPS 270 MLD) Surface Water (Red Hills 300 MLD) Surface Water (Veeranam 180 MLD) Surface Water (Chembarambakkam- 530 MLD) Surface Water (Surapet 14 MLD) Ground Water (Well Fields 15 MLD) Desal Water (100 MLD) - DBOOT Desal Water (100 MLD) EPC (To be on stream by 2012) Cost per Kilo litres in Rs. 5.48/4.78/10.50/8.04/5.11/28.72/48.66/20.64/-

* Total Water Treatment Capacity available = 1400 MLD