annexure 8 map showing proposed green belt...

FAIRDEAL TEXTILE PARK PVT. LTD. Prepared by : EN‐PRO Enviro Tech And Engineers Pvt. Ltd.

Annexure – 8

Map Showing Proposed Green Belt Along With

Details Plan Of Greenbelt Development.


Annexure – 9

Layout of Textile Park

FAIRDEAL TEXTILE PARK PVT. LTD.

Prepared by : EN‐PRO Enviro Tech And Engineers Pvt. Ltd.

Annexure – 10

Treatability Study On Industrial Effluent.

REPORT

ON

TREATABILITY STUDY CONDUCTED

ON WASTE WATER

FOR

M/S FAIRDEAL TEXTILE PARK Village: Mahuvej, Dist: Surat

By

Daystar Enviro Technologies Pvt. Ltd.

204-208, Silver Coin, Near Shrenik Char Rasta,

Akota, Vadodara - 390020

I N D E X

SR. NO. TITLE

0.0 EXECUTIVE SUMMARY

1.0 INTRODUCTION

2.0 AIM OF STUDY

3.0 SAMPLE COLLECTION

4.0 ANALYSIS OF WASTEWATER SAMPLES

5.0 TREATABILITY STUDY

6.0 PLAIN SETTLING

7.0 PHYSICO CHEMICAL TREATMENT

8.0 ACTIVATED SLUDGE PROCESS

9.0 TERTIARY TREATMENT

10.0 RESULTS & DISCUSSION

11.0 CONCLUSION

12.0 TABLES OF EXPERIMENTAL DATA

EXECUTIVE SUMMARY M/s Fairdeal Textile Park is being proposed as industrial infrastructure for industries such as

Yarn Texturising & Polyelectrolyte weaving units. A major portion of Textile Park shall be for

industries using Water Jet Looms.

The Textile Park being an upcoming project, wastewater samples were collected for carrying

out the treatability study, from existing industry having identical production unit set up.

The wastewater collected was allowed to settle for a period of 15 M to 2 hours, for removal

of free oil. The experiments indicated about 70% removal of free oil within 30 Min. The

wastewater was then subjected to physico chemical treatment using various chemicals like

FeSO4, FeCl3 & Alum. Different doses were triad and finally a dose of 200 mg/lit Alum & 2

mg/lit Polyelectrolyte provided good results; as indicated by COD reduction. The effluent

after physico chemical treatment was subjected to biological treatment in an Activated

Sludge Process.

Initially experiments were carried out as batch system keeping F/M ratio to 0.15 & MLSS

levels to 3000 mg/lit. The experiments were started using sewage sludge. After the

acclimatization period COD & BOD measurements were carried out. In the batch process it

was observed that good reduction of COD & BOD is achieved at hydraulic retention time of 8

hrs. After getting an idea from the batch a continuous aerobic system was run in the

laboratory for about three weeks.

The outlet samples were drawn and analyzed for parameters such as pH, COD, BOD, &

MLSS. It was observed that after stabilization the COD & BOD values of treated wastewater

were 15 mg/lit & less than 10 mg/lit.

The effluent after biological process was further treated by passing it through Graded Sand

Media & Activated Carbon column filter. This treatment had further reduced the COD & BOD

& the finally treated wastewater indicated COD of 10 mg/lit & BOD of less than 10 mg/lit;

which was as per the plant requirement of Reuse water.

The summary results of the treatability study are given in the report. Based on the treatability

study conceptual flow diagram of the proposed treatment facility is as given in enclosure-I.

Treatability study conducted for M/s Fairdeal Textile Park Village: Mahuvej, Dist: Surat 1.0. INTRODUCTION

Water is used as an important utility in operation of Water Jet Loom. The quality of

water is very important for smooth operation of the looms. As per the plant

specification the water used for Water Jet Looms shall have dissolved impurities

(Total dissolved salts) of less than 200 – 250 mg/lit & organic matter in negligible

concentration.

During the process of weaving of synthetic fabric using Water Jet Looms synthetic oil

(coning oil) applied to the synthetic threads is removed due to friction of water with

the fibre. The water used in Water Jet Looms is ultimately collected in the looms area

& is led to the collection sump. This water contains, soluble oil, free oil from

machines, small pieces of broken fibre & dirt, & is now termed as wastewater.

The wastewater when analyzed indicates pollutants, represented by COD, BOD, Oil

& Grease etc. & the higher value of the pollutants calls for its treatment.

Reuse of wastewater is an economical alternative to reduce fresh water use. To

establish the possibility of wastewater treatment & its reuse at the proposed Textile

Park a treatability study was carried out using wastewater from existing similar type

of industry.

2.0. AIM OF STUDY

Aim of the study was to achieve the treated wastewater quality as per reuse water

standards, indicated by the client; which is as given below.

Sr. No. Parameters Units Value

1 pH – 6.5 – 8.0

2 COD mg/lit < 30

3 BOD mg/lit < 10

4 Suspended Solids mg/lit < 10

5 Oil & Grease mg/lit < 10

6 TDS mg/lit 250

3.0. SAMPLE COLLECTION

To collect the samples and to understand wastewater generation locations, &

frequency a Textile unit using about 400 water Jet Looms, Near Kim was visited on

different dates. During the factory visit it was observed that wastewater is generated

at different times & at different flow rates. For this reason it was decided to collect

composite samples over a period of 24 hours. The samples were brought to

Laboratory and analyzed.

4.0. ANALYSIS OF WASTEWATER SAMPLES

The samples collected from the factory were analyzed for various parameters & the

analysis results are as given in Table No.: 1. The analysis reports indicated

comparatively constant value.

5.0. TREATABILITY STUDIES

The composite samples as received from the site were stored at 200C & used to

carry out the treatability study. Fresh samples were collected as and when required

for the treatability study.

6.0. PLAIN SETTLING

The wastewater indicates presence of free oil & hence sample was taken for plain

settling up to 2 hours. Settled sample was collected & analyzed for oil & grease. The

results are given in Table No.: 2.

7.0. PHYSICO CHEMICAL TREATMENT

The settled samples was subjected to chemical treatment; using FeSO4, FeCl3, Alum,

Polyelectrolyte. The results of above treatment are given in Table No.: 3.

8.0. ACTIVATED SLUDGE TREATMENT

The effluent after Alum + Polyelectrolyte treatment was subjected to Activated

Sludge Process. Initially a batch reactor was operated & subsequently a continuous

reactor was operated for a period of 3 weeks. During the trial MLSS in the reactor

was maintained at 3000 mg/lit. Required quantity of Nitrogen & phosphorus was

added in the reactor. Samples were collected at specified time intervals and analyzed

for COD & for a few sets for BOD. The results of Laboratory work are given in Table

No.: 4, 5 & 6.

9.0. TERTIARY TREATMENT

Activated Sludge Process outlet treated with Graded Sand Media Filter & Activated

Carbon. The results are as given in Table No.: 7 & 8.

10.0. RESULTS & DISCUSSION

Wastewater samples from existing textile unit was collected & analyzed to confirm

concentrations of various parameters. The treatability study was conducted on

composite samples collected & stored in Laboratory at 200C.

The wastewater was treated in below indicated treatment stages.

• Plain Settling

• Physico Chemical Treatment

• Activated Sludge Process

• Graded Sand Filtration

• Activated Carbon Filtration The plain settling have indicated good free oil removal capability and about 70% oil

reduction was observed in less than 30 minutes.

In the chemical treatment results were not encouraging with use of FeSO4, FeCl3 but

good results were obtained in using Alum with Polyelectrolyte. The wastewater after

chemical treatment showed good clarity & reduction of COD. The treated wastewater

after chemical treatment was subjected to biological treatment in on Activated Sludge

Process.

The processes of biological treatment have indicated vary encouraging results and

have provided COD / BOD reduction of more than 90%.

The treated wastewater was further treated by passing it through graded sand media

followed by Activated Carbon. The treatment had provided good reduction in

suspended solids & COD / BOD removal. During the treatment process the TDS

increase was very marginal as found by analyzing representative samples during

treatability period.

11.0. CONCLUSION

Form the above study it is clear that wastewater generated in proposed Textile Park

can very well treated applying physico-chemical, biological & polishing filtration

methods to achieve desired treated wastewater quality.

12.0. TABLES OF EXPERIMENTAL DATA

TABLE NO.: 1

Analysis of wastewater samples – January to February 2010

Sr. No.

Parameters

Colour pH TDS SS COD BOD Oil & Grease

1 Milky White 6.5 255 98 350 200 112

2 Milky White 6.0 200 160 290 190 96

3 Milky White 7.0 190 80 260 200 90

4 Milky White 6.6 150 100 310 230 130

5 Milky White 7.3 200 105 260 160 80

6 Milky White 6.8 160 110 300 190 160

TABLE NO.: 2

Primary Treatment (Plain Settling) Sr.

No.

Settling Time Oil & Grease (mg/lit) Suspended Solids (mg/lit)

Untreated After settling Untreated After settling

1 15 minutes 110 90 100 100

2 30 minutes 110 30 100 80

3 45 minutes 110 25 100 80

4 90 minutes 110 25 100 75

TABLE NO.: 3

Physico Chemical Treatment

Sr. No.

Treatment Dose (PPM)

pH COD TSS (mg/lit) (%) Redn. (mg/lit) (%) Redn.

Control Sample 7.0 280 – 100 –

1 Alum 50 6.5 210 25.0 90 10

100 6.5 150 46.4 50 50

200 6.4 140 50.0 40 60

2 FeCl3 20 6.0 250 10.7 90 10

100 5.5 230 17.8 90 10

200 5.0 210 25.0 80 20

3 FeSO4 50 7.0 240 14.3 85 15

100 7.0 230 17.8 80 20

200 7.0 200 28.6 80 20

Note: 2 mg/lit of polyelectrolyte was added in all above experiments.

TABLE NO.: 4

Activated Sludge Process (Batch Reactor) – 1st Set (with raw settled wastewater)

Sr. No.

Aeration Time (hrs.)

pH COD

BOD

mg/lit (%) Redn. mg/lit (%) Redn.

1 0 6.8 290 – 200 –

2 8 7.0 110 62 90 55

3 16 7.1 60 79 80 60

4 24 6.9 50 82.5 70 65

5 32 7.0 50 82.5 60 70

6 40 6.9 50 82.5 60 70

TABLE NO.: 5

Activated Sludge Process (Batch Reactor) – 2nd Set (with pretreated wastewater)

Sr. No.

Aeration Time (hrs.)

pH COD

BOD

mg/lit (%) Redn. mg/lit (%) Redn.

1 0 6.9 140 – 100 –

2 8 7.0 60 57.0 30 70

3 16 7.1 50 64.3 25 75

4 24 6.9 50 64.3 25 75

5 32 6.9 40 71.4 25 75

6 40 7.1 40 71.4 20 80

TABLE NO.: 6

Activated Sludge Process (Continuous Reactor)

Primary Treated Wastewater with Alum & Poly Treatment Feed Quality – pH – 7.0 COD – 160 BOD – 90

Sr. No.

Values % Reduces

Remarks

pH COD (mg/lit)

BOD (mg/lit)

COD

BOD

1 7.0 50 30 68.75 66.7 F/M = 0.15 2 6.8 50 – 68.75 – MLSS = 3000 mg/lit 3 7.0 50 – 68.75 – VSS = 2400 mg/lit 4 7.0 40 – 75 – 5 7.0 40 25 75 72.2 HRT = 8 hrs 6 7.0 40 – 75 – 7 7.0 40 – 75 – 8 6.7 50 – 68.75 – 9 6.9 60 30 62.5 66.7

10 6.9 50 – 68.75 – 11 7.0 40 – 75 – 12 7.0 40 – 75 – 13 7.0 40 20 75 77.7 14 6.8 30 – 81.2 – 15 6.8 40 – 75 – 16 7.0 30 – 81.2 – 17 7.0 30 15 81.2 83.3 18 6.9 20 – 87.5 – 19 6.9 15 – 90.6 – 20 6.8 15 – 90.6 – 21 6.9 15 10 90.6 91 22 6.8 15 – 90.6 – 23 6.9 15 – 90.6 – 24 6.9 15 – 90.6 – 25 9.9 15 10 90.0 91

Note: 1) Sludge settalability in the Aeration Tank was good.

2) Nutrients such as DAP & Urea was added once a week.

TABLE NO.: 7

Treatment of Activated Sludge Reactor Outlet with Sand Media Filter (1) Feed Quality

1) COD – 40 (mg/lit)

2) BOD – 15 (mg/lit)

3) Suspended Solids – 60 (mg/lit)

4) pH – 7 (2) Filter Column Details (Sand Media Filtration)

• Column Diameter – 25.4 mm

• Height of column – 1200 mm

• Filtration rate – 10 m3 / m2 / hr

• Filter Media – Graded Sand & Pebbles

Sr. No. Sampling Time (in minutes)

Filtrate Quality

Suspended Solids (mg/lit)

COD (mg/lit)

BOD (mg/lit)

pH

1 30 < 10 35 – – 2 60 (1 hr) < 10 35 – – 3 120 (2 hrs) < 10 35 – – 4 480 (8 hrs) < 10 30 – – 5 Composite sample < 10 35 15 7.0

TABLE NO.: 8

Treatment of Sand Media Filter Outlet with Activated Carbon Filter

(1) Feed Quality

5) COD – 35 (mg/lit)

6) BOD – 15 (mg/lit)

7) Suspended Solids – < 10 (mg/lit)

8) pH – 7 (2) Filter Column Details (Activated Carbon Filtration)

• Column Diameter – 25.4 mm

• Height of column – 1000 mm

• Filtration rate – 10 m3 / m2 / hr

• Filter Media – Activated Carbon with iodine value 800

Sr. No. Sampling Time (in minutes)

Filtrate Quality

Suspended Solids (mg/lit)

COD (mg/lit)

BOD (mg/lit)

pH

1 30 < 10 BDL – – 2 60 (1 hr) < 10 BDL – – 3 120 (2 hrs) < 10 BDL – – 4 480 (8 hrs) < 10 15 – – 5 Composite sample < 10 10 < 10 7.0

SUMMARY RESULTS OF TREATABILITY STUDY pH – 6.5 – 7.3 COD – 280

Raw Wastewater BOD – 210 TDS – 230 SS – 100 O&G – 110 After Plain Settling O&G – 30 (30 Mtrs) SS – 80 After Physico

Chemical Treatment pH – 6.9 Alum – 200 mg/lit COD – 140 mg/lit Poly – 2 mg/lit SS – 40 mg/lit After Activated pH – 6.9 Sludge Process COD – 15 mg/lit BOD – 10 mg/lit pH – 7.0 After Activated COD – 15 mg/lit Carbon Filtration BOD – < 5 mg/lit SS – < 10 mg/lit

Considering above treatability study CETP was designed, which comprises of following units. [A] Civil Units: Sr. No.

Description Size Nos. MOC Capacity m3

Residence Time

1 Inlet Chamber 4.2 M x 4.2 M x 2 MLD + FB 1 RCC 35 5 Min

2 Screen Chamber 8 M x 1 M x 1 MLD + FB 2 RCC 16 2 Min

3 Free Oil Removal Chamber 22.5 M L x 2.5 M x 2 M + FB 2 RCC 225 32 Min

4 Equalization Tank (3 Hrs. Holding Period)

22.5 M x 12.5 M x 2 MLD + FB 2 RCC 1125 2.7 Hrs

5 Flash Mixer Tank 3M x 3M x 1.2 MLD + 0.5 M FB 1 RCC 9 1.3 Min

6 Flocculator Tank 7.5 M x 7.5 M x 2.5 MLD + 0.5 M FB 1 RCC 140 20 Min

7 Primary Clarifier 21 M Dia x 3 MLD 1 RCC 1038.5 2.5 Hrs

8 Aeration Tank 30 M x 15 M x 4 MLD + 0.5 M FB 2 RCC 3600 8.5 Hrs

9 Secondary Clarifier 23 M Dia x 3 MLD + 0.5 M FB 2 RCC 2490 3.5 Hrs with recycle flow

10 Clarified Wastewater Tank (2 Hrs.) 17 M x 16.5M x 3 MLD + 0.5 M FB 1 RCC 841.5 2 Hrs

11 Treated Wastewater Tank (3 Hrs. cap.)

20 M x 20 M x 3.25 MLD + 0.5 M FB 1 RCC 1400 3.4 Hrs

12 Alum Solution Tank 1.5 M x 1.5 M x 1.2 MLD + 0.5 M FB 1+1 RCC 2.7 8 Hrs

13 Poly. Solution Tank (Pretreatment) 3 M x 2.5 M x 2 MLD + 0.5 M FB 1+1 RCC 15 8 Hrs

Sr. No.

Description Size Nos. MOC Capacity m3

Residence Time

14 Sludge Tank 5.5 M x 5 M x 2.5 MLD + 0.5 M FB 1 RCC 68.75 12 Hrs

15 Poly. Solution Tank (Centrifuge) 1.5 x 1.5 x 2 MLD +0.5M FB 1 RCC 4.5 –

16 Thickener Basin 6.5 M Dia x 2.5 MLD + 0.5 M FB 1 RCC – –

17 Thickened Sludge Tank 3.5 M x 3.5 M x 2.5 MLD + 0.5 M FB 1 RCC 30 –

18 MCC / Operating Room 18 M x 6 M x 4 M 1 RCC – –

19 Chemical Dosing Tank Area 10 M x 6 M x 4 M 1 RCC – –

20 Chemical Store 10 M x 6 M x 4 M 1 RCC – –

21 Centrifuge Shed 5 M x 8 M x 4 M 1 RCC – –

22 Sludge Shed 5 M x 10 M x 4 M 1 RCC – –

23 Centrate Sump 3.5 M x 3.5 M x 2 MLD + 0.5 M FB 1 RCC 24.5 –

[B] Mechanical Units: Sr. No.

Description Size Nos. MOC Remarks

1 Screen (Manual) 1 M Wide 2 MSEP –– 2 Oil Skimmers for Free Oil Reciprocating Type 2 SS / MSEP –– 3 Agitators 7.5 HP 4 MS / SS –– 4 Transfer Pumps 210 m3/hr x 1.5 kg/cm2 2+1 CI / CI –– 5 Flash Mixer (Mech.) 1.5 HP 1 MS –– 6 Flocculator (Mech.) 3 HP 1 MS –– 7 Primary clarifier Mechanism 21 M Dia x 3 MLD 1 MSEP –– 8 Air Blowers 2500 m3/hr x 0.55 kg/cm2 2+1 CI –– 9 Air Diffusers (Retrievable Type) 2 M Long 330 Silicon Rubber ––

10 Clarifier Mechanism 23 M Dia x 3 MLD 2 MSEP –– 11 Sludge Recycle Pumps 125 m3/hr x 1.5 kg/cm2 2+1 CI –– 12 Filter Feed Pumps 115 m3/hr x 2.5 kg/cm2 4+1 CI –– 13 Pressure Sand Filter 3.6 M Dia x 1.7 M Ht 4+1 MSEP –– 14 Activated Carbon Filter 3.6 M Dia x 1.8 M Ht 4+1 MSEP –– 15 Backwash Pump 200 m3/hr x 1.5 kg/cm2 1 CI –– 16 Backwash Blower 385 m3/hr x 0.15 kg/cm2 1 CI / CI Standby not required 17 Treated Wastewater Transfer Pump To be decided later - CI / CI These pumps shall be installed

as per requirement for transferring the treated wastewater to individual ind.

18 Agitator – Alum Soln. Tank 1.5 HP 1+1 SS-316 –– 19 Agitator – Poly. Soln. Tank 2.0 HP 1+1 SS-316 –– 20 Dosing Pump

AlumPoly

0-500 LPH x 4 kg/cm2 0-750 LPH x 4 kg/cm2

1+1 2+1

SS / PP SS / PP

––

21 Poly. Tank Agitator 1.0 HP 1 SS-316 –– 22 Poly. Dosing Pump (Centrifuge) 0-100 LPH x 4 kg/cm2 1+1 SS-316 –– 23 Thickener Feed Pump 4 m3/hr x 1.5 kg/cm2 1+1 CI ––

Sr. No.

Description Size Nos. MOC Remarks

24 Thickener Mechanism 6.7 M Dia x 2.5 MLD 1 MSEP –– 25 Centrifuge Feed Pump 2 m3/hr x 4 kg/cm2 1+1 CI / SS Screw Pump 26 Centrifuge Machine 2 m3/hr feed capacity 1+1 MS / SS –– 27 Pump Operating Panel As per requirement 1 MSEP –– 28 Interconnecting Piping As per requirement Lot MS / HDPE –– 29 Centrate Transfer Pump 10 m3/hr x 1.5 kg/cm2 1+1 CI To transfer Centrate to

receiving sump 30 Interconnecting Cables &

Accessories As per requirement 1 Lot – ––

31 Instruments a) Pressure Gauges b) Level Switch c) Flow Meter

Pump outlet & filter inlet outlet Equalization tank & clarified water tank Inlet of flash mixer & outlet of activated carbon filter

Lot

1 each

1 each

–

SS

SS / MS

–– ––

––

FAIRDEAL TEXTLE PARK PVT. LTD. Prepared by : EN‐PRO Enviro Tech And Engineers Pvt. Ltd.

Annexure – 11

SAMMATIPATRA Received from Plot

Owners


Annexure – 12

Compliance report on CPCB Guidelines For

Management, Operation And Maintenance Of

Common Effluent Treatment Plants


Sr. No.

Condition Compliance

1

Management System FTPL shall established management system for Membership to the CETP, Wastewater collection, Monitoring and performance of treatment units, manpower management and maintenance of CETP.

2

Membership to the CETP FTPL is Private Limited company. FTPL shall submit member list along with effluent load details to GPCB on regular basis. FTPL shall accept effluent only from valid member textile industries through underground pipeline. FTPL shall regularly monitor the effluent quality and quantity sent to CETP by visiting member industries. If any member found discharging effluent quality /quantity exceeding than prescribed norms they shall be charged with penalties.

3

Collection System FTPL shall lay down effluent conveyance pipeline of 10 MLD capacity, for conveyance of effluent from member industry to CETP. FTPL shall collect effluent sample from equalization tank of member industry on regular basis FTPL shall provide under ground collection sump to collect effluent from member industry followed by equalization tank.

4

Guidelines for operation of various units of CETP

FTPL shall provide effluent collection sump followed by Equalization tank of adequate size FTPL shall provide dosing tanks of treatment chemicals, flash mixer, and clariflocculator as primary treatment facility. FTPL shall provide aeration tank as biological treatment units. The details of CETP units along with capacity of each unit are given in Chapter -2, point 2.6.


5 Manpower requirement FTPL shall provide well qualified staff for smooth operation of CETP.

6

Monitoring and Performance FTPL shall regularly monitor the effluent quality and quantity sent to CETP by visiting member industries. If any member found discharging effluent quality /quantity exceeding than prescribed norms they shall be charged with penalties and there effluent is not accepted by CETP until the quality and quantity is matched with prescribed norms.

7

Maintenance All pumps, mechanical devices, motors are regularly checked and greasing shall be done weekly. The break downs shall be attended immediately. And cause of the break downs shall be taken care permanently.

8 Trouble Shooting The operatory and chemists shall be given training for routine trouble shooting


Annexure – 13

Drawings and Details

of Effluent Conveyance System


Annexure – 14

Undertaking – Conducting audiography and not allowing dyeing

and printing units in FTPL

annexure 8 map showing proposed green belt...

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